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Number 375 March | April 2018
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SULPHUR
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SULPHUR
■ CONTENTS
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What’s in issue 375
Welcome to our interactive
5
6
7 version of Sulphur Issue 375 www.sulphurmagazine.com ■ COVER FEATURE 1

Number 375
8 Middle East
Please use either the buttons on the left or top Sulphur
9 right of the page to navigate your way around this Conference,
10 interactive PDF Abu Dhabi
11 IMPORTANT INFORMATION:
Copyright – Issued six times per year, or bi-monthly. All rights reserved. No part of
12 this publication may be reproduced, stored in a retrieval system or transmitted in any ■ COVER FEATURE 2
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– without the prior written permission of the Copyright owner.
13 North Africa’s
14 phosphate industry
15
■ COVER FEATURE 3
16

www.sulphurmagazine.com
17 SRU combustion
challenges
18
19
■ COVER FEATURE 4
20
Sulphuric acid
21
plant simulation
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Middle East Sulphur Conference, Abu Dhabi ISSUE 375
SULPHUR

MARCH-APRIL 2018
27
28 North Africa’s phosphate industry
29

SRU combustion challenges

March | April 2018

30
31

Sulphuric acid plant simulation

Southbank House, Black Prince Road
32 London SE1 7SJ, England
Tel: +44 (0)20 7793 2567
33 Fax: +44 (0)20 7793 2577
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SULPHUR
2
3
Proven Sulphur Technologies for ■ CONTENTS
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5
Capital-Efficient Solutions that Meet www.sulphurmagazine.com What’s in issue 375
6 Clients’ Environmental Requirements NUMBER 375 March | april 2018

7 ■ COVER FEATURE 1

8 Middle East
Our experts at Fluor are experienced in all commercially For more information Sulphur
9 cONTENTS
proven sulphur technologies and develop solutions please contact: Conference,
cover: The Capital Gate Tower, Abu
10 that cost-effectively satisfy our clients’ environmental Thomas Chow Dhabi stands at 160 m tall and leans at 10
18 The centre of the sulphur world? Abu Dhabi
requirements. Our offerings include: Vice President, Fluor Sulphur an astounding 18 degrees to the west. Tapping of sour gas fields and continuing refinery expansions will see the
11 Alan64/iStockphoto.com Middle East continue to become increasingly dominant on the sulphur export
` Licensing COPE® oxygen enrichment technology for Technology
12 sulphur plant capacity expansion
scene over the next few years. ■ COVER FEATURE 2
949.322.1200. tel
thomas.chow@fluor.com 12
22 North african phosphates
13 ` Licensing D’GAASS® liquid sulphur degassing North Africa continues to be a major growth area for sulphur demand. As well North Africa’s
www.fluor.com
14 technology for environmental benefits as the continuing expansion of OCP’s phosphate processing capacity there are phosphate industry
also new projects in Tunisia and Egypt, and potentially also Algeria.
` Licensing hydrogenation/amine and FLEXSORB® Claus © 2018 Fluor Corporation. All rights reserved.
15 Fluor, COPE, and D’GAASS are registered 15
28 Sulphur World Symposium 2018
Tail Gas Treating for 99.9+% overall sulphur recovery

12 ■ COVER FEATURE 3
service marks of Fluor Corporation.
efficiency The Sulphur Institute’s annual World Sulphur Symposium comes to the
16 FLEXSORB® is a registered trademark and
Loews Philadelphia Hotel in Philadelphia, PA, from April 23rd – 25th 2018.
proprietary process name of ExxonMobil
17 ` Sulphur recovery unit, tail gas treating unit and and its affiliates.
North African phosphates 16
SRU combustion
degassing plant ranges from 10-ton-per-day to 30 Sulphur recovery project listing
A major source of sulphur demand Sulphur’s annual survey of recent current and future sulphur recovery unit challenges
18 2,600-ton-per-day single trains over the coming years. construction projects maps the developing shape of brimstone production from
19 fuel and gas processing plants worldwide.

18
34 The digital world of sulphuric acid
■ COVER FEATURE 4
20
Simulator engines have come a long way from their humble beginnings. In this
Sulphuric acid
21 article Chemetics, Haldor Topsoe, Noram and Outotec report on some of the
latest developments and applications of simulation and modelling to improve plant simulation
22 the profitability, design and operation of sulphuric acid plants.

23 25
49 combustion challenges in the reaction furnace
In this article Duiker examines some important performance aspects of the
24 reaction furnace; Siirtec Nigi reports on its improved SRU thermal section;

18
Blasch discusses its latest developments for SRU reaction furnace internals;
25 SULPHUR

ISSUE 375
and Jacobs introduces a useful tool for temperature monitoring in the
reaction furnace.
26 Sulphuric acid plant
simulation MARCH-APRIL 2018
27 rEGUlarS
Improving efficiency through
28 modelling. 3
4 Editorial
Reality begins to dawn.
29
Read this issue online at: 4
6 price Trends
30 www.sulphurmagazine.com 5
8 Market Outlook
31 Published by: 6
10 Sulphur industry News
Southbank House, Black Prince Road
32 7
13 Sulphuric acid News London SE1 7SJ, England
Tel: +44 (0)20 7793 2567
33 9
16 people/calendar
Fax: +44 (0)20 7793 2577
Web: w ww.bcinsight.com
www.bcinsightsearch.com
ADHO159818
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2
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Editorial
■ CONTENTS
4
5
6
Reality begins What’s in issue 375

to dawn
7 ■ COVER FEATURE 1

8 Middle East
Sulphur
9
Conference,
W
e are now less than two years from the capability. Likewise port states are not authorised to
10 time when all ships must be either run- police the rule – only flag states – the country which Abu Dhabi
ning on fuel with a sulphur content of less licenses a ship to operate – are currently allowed
11 than 0.5%, or else have remedial measures in place to enforce the standard. However, the IMO is fully
to scrub their engine exhausts, and it feels as if the aware of this and its members seem to be taking a
12 cold, hard reality is finally beginning to dawn upon firm stance. It has charged its Pollution Prevention ■ COVER FEATURE 2
the shipping and other industries – this is going to and Response (PPR) sub-committee with taking the
be chaotic, and potentially quite expensive. lead role on the enforcement issue, and in a recent
13 North Africa’s
Perhaps one of the biggest surprises in the run- meeting PPR identified four main mechanisms for
14 up to the January 1st 2020 deadline (the IMO had tightening enforcement, chief among which is author- phosphate industry
the option of delaying this to 2025, but has decided ising port states to enforce compliance. A new report
against it) is the lack of penetration of exhaust by insurance broker Marsh: Emissions Regulations:
15 scrubbing technologies. So far, less than 1% of Concerns for the Marine Industry, points out to ship
■ COVER FEATURE 3

“
cargo vessels covered by the legislation (about 400 owners that ships that are found out of compliance
16 out of 60,000 ships) have so far installed scrub- potentially face losing seaworthiness certificates,
bers or placed firm orders to do so. Some of this flag state convention certification, and possibly even
17 comes down to concerns over corrosion, and uncer- insurance cover. Other levers include garnering sup-
SRU combustion
This is going tainty over the cheapest form of scrubbers – open port from large receivers of shipped goods to use challenges
18 to be chaotic, loop wet scrubbers, which discharge acidified waste only vessels that comply with the regulations to
directly into the sea – and whether there is likely to avoid negative consumer sentiment, or even prohib-
19 and potentially be a future crackdown on this. But, as evidenced by iting vessels without onboard scrubbers from trans-
quite expensive. a recent report by shipping line Pacific Basin, most porting fuel oil with a sulphur content greater than ■ COVER FEATURE 4
20 ship owners simply do not believe that they are prac- 0.5%. The only get-out looks likely to be a so-called
tical or cost effective. Maersk has already said that FONAR – Fuel Oil Non-Availability Report – specifying
Sulphuric acid
21 it will not use scrubbers for Annex VI compliance, that low sulphur fuel was not available at the port
and Shell believes that by 2020 only 1,500 ships when the ship fuelled. The shipping industry is some- plant simulation
22 (2.5% of cargo vessels) will have been converted to what belatedly starting to realise that 2020 could be
run on scrubbers. a very difficult year indeed.
23 Likewise penetration of alternative fuels has so It is likely too late even for a last minute rush for
far been relatively small. Less than 0.5% of ships scrubbers or alternate fuel engines to make much
have been designed or converted to operate on of a difference. Now the question is whether refiners
24
LNG, methanol or other, and take-up by 2020 is will invest in desulphurisation capability in advance

25 unlikely to be more than 1%. The upshot is that this of the deadline, in anticipation of being able to take SULPHUR

ISSUE 375
will leave 96.5% of ships that fall under the legisla- advantage of a spike in low sulphur fuel demand,
tion having to rely on purchasing marine gasoil or or whether they wait and see how things shake out.
26 other low sulphur refined fuels come January 2020, Either way, there are significant costs ahead for
and the ability of the refining industry to supply suf- someone, whether it is the ship owner, the refiner MARCH-APRIL 2018
27 ficient fuels is very much in doubt. or the consumer, and probably all three. n
There has been a slightly blithe assumption from
28 the shipping industry that the rule may simply prove
to be unenforceable, and that in many cases it might
29 be preferable to try and front it out – continue using
high sulphur fuel oil and gamble on not being caught
30 or prosecuted, and where that happens, simply
accept whatever fines are handed down. Perhaps
31 large-scale non-compliance might even force the
IMO into a re-think about not extending the deadline Southbank House, Black Prince Road
32 to 2025, the thinking goes. The IMO is after all a London SE1 7SJ, England
United Nations organisation and has no enforcement Richard Hands, Editor Tel: +44 (0)20 7793 2567
33 Fax: +44 (0)20 7793 2577

4 www.sulphurmagazine.com Sulphur 375 | March - April 2018 Web: w ww.bcinsight.com

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2 price trends

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Price trends
■ CONTENTS
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5 MARKET INSIGHT
ket, and to a lesser extent the sulphuric balance. The project so far has had no For sellers in Japan and Korea, spot sul- ment were sufficient that shipments of What’s in issue 375
acid market, for its raw material to upgrade impact on the international sulphur mar- phuric acid prices have been relatively flat virgin acid from China were agreed, with
Oliver Hatfield, Director, Fertilizer Research Team, Integer Research phosphate rock to intermediate and fin- ket, with sulphur movements understood during the first two months of the year at three 20,000 tonne cargoes reported to
6 (in partnership with ICIS) assesses price trends and the market ished products. Increased investment in to be slow, but the prospect is getting around $25/t, which is about $10/t lower have been settled in December at $40/t

7 outlook for sulphur. this processing capacity meant the com- closer. Oil and gas production volumes than the peak 2017 level, seen in Septem- f.o.b. China. These shipments illustrated ■ COVER FEATURE 1
pany increased its sulphur imports to more are increasing, with current oil produc- ber and October, but February 2018 prices that although spot sulphur prices were
than 3 million tonnes in the second half of tion reported at 300,000 barrels per day, are still above the 2017 annual average. Jap- significantly weaker than their November
8 stocks have since recovered substantially the 2017, compared to around 2.4 million compared to a target output level for the anese and South Korean sellers were selling highs, they were still sufficiently inflated to Middle East
SULPHUR
and in February 2018 reached around 1.4 tonnes in the first half. It’s likely that Q4 year of 370,000 barrels per day which at negative netbacks as recently as January support buoyant sulphuric acid prices. Sulphur
9 Compared to the frantic activity seen dur- million tonnes. We now have the benefit of imports would have been higher but OCP is expected to be reached by the middle 2017, and the recent low point saw negative While some metals buyers could afford
ing the last few months of 2017, the first hindsight to consider the nominal amount was frustrated after the cancellation of its of 2018. In China there are a handful of values dip to negative $22/t in May 2016. higher acid prices, other buyers were feel- Conference,
10 two months of 2018 felt a bit like the calm of Chinese imports during the rally. It is contract shipments for that period from projects which are expected to boost the Market sentiment continues to be tight ing the pinch from acid price inflation. In Abu Dhabi
after the storm. After falling during the first interesting that imports in each of the Russia due to weather-related logistics country’s sulphur output by around 1 mil- in 2018. In Europe spot availability for the Brazil, some phosphate buyers were put
11 week of January 2018, the spot price of last three months of the year amounted disruption. Consequently, North African lion tonnes, which is likely to be sufficient first half of 2018 is reported to be tight. off sufficiently to scrap tenders. In India,
solid sulphur delivered to China was flat to 0.8-0.9 million tonnes, around 100,000 sulphur prices moved up with other spot to reduce Chinese demand for sulphur Likewise, the substantial loss of acid sup- negotiations over 2018 contracts became
12 during the rest of January and February tonnes per month less than the previous sulphur prices, though for quarter contract imports. Once these projects are up and ply volumes in East Asia at end of 2017, protracted, with buyers offering East Asian ■ COVER FEATURE 2
at around $135-140/t c.fr. Similarly, the quarter. For the last quarter of 2018, shipments there was a substantial lag running they will lead to increased export due to maintenance at smelter producers, suppliers $30-40/t c.fr, while sellers were
spot f.o.b. Vancouver reference flatlined China imported around 0.5 million tonnes behind spot levels. availability and reduced import demand, is still having a significant effect on export $10/t higher. A compromise was report-
13 North Africa’s
at around $125/t f.o.b. during February less than in Q3 2017. This illustrates that There remains significant uncertainty and weaker sulphur prices will follow. availability this year. Producers are consist- edly agreed on some deals by linking acid

14 having lost around $30/t during the first the tight market could not be explained in the sulphur market concerning the near ently reported to be short on spot supply prices to a third of the delivered India phosphate industry
three weeks of the year. The drop in prices solely by increased Chinese imports. term direction of prices because the market SULPHURIC ACID for the whole of the first half of 2018. Not sulphur price, less a % discount. Short of
was to be expected given how rapidly Supply limitations were a contributing remains finely balanced. Recent monthly surprisingly in that environment, contract regular sulphur supplies in Q4 2017, OCP
15 prices had increased at the end of 2017. factor. Availability of exports from the Mid- price announcements for March illustrate The start of 2018 has seen sulphuric negotiations and agreements are showing of Morocco was still active in the acid mar-
The delivered China reference topped out dle East were reduced by the start-up of this. Prices had been falling, but Saudi Ara- acid prices rising in most markets. With price inflation. Some Asian contract agree- ket in the first two months of 2018. Trade ■ COVER FEATURE 3
16 at around $220/t, the highest level since the Ma’aden phosphate project in Saudi mco announced it was increasing prices by the odd relatively short-term correction or ments for Q1 2018 were agreed at $30/t, data shows that OCP imported 1.6 mil-
February 2014. Arabia which increased domestic sulphur $15/t to $135/t. Muntajat announced a flat spell, prices have increased almost up $10/t. lion tonnes of acid in 2017, up by around
17 Recent prices are still substantially demand in the second half of 2017. We similar increase to $134/t. On the other uninterrupted since the first half of 2016. Supply disruptions continue to impact 160,000 tonnes on 2016, and around
SRU combustion
higher than levels seen during the major- can now see that H2 2017 Saudi Ship- hand, Adnoc announced it March Official The NW European spot acid price reached the market balance. The PASAR opera- 670,000 tonnes than in 2015. challenges
18 ity of 2017, and the subsequent correc- ments to the US were lower by around Selling Price (OSP) to the India market at $40/t in the second half of February tion in the Philippines which can pro- The sulphuric acid market is expected
tion has seen values level off to those 200,000 tonnes compared to the first half $140/t, a rollover from February. Optimism 2018, almost double the level seen in duce around 50,000 tonnes per month, to be tight during the first quarter at least
19 seen in September 2017, when the rally in of the year. Export shipments from Iran about prices is founded on the expectation November 2017. There are some reports declared force majeure due to a typhoon. and likely Q2 as well. It’s not entirely clear
prices really accelerated. For most of the were also notably lower in the last quarter that demand from China will be relatively that spot European cargoes have moved Industrial action in Chile reduced domestic yet whether the market balance is such ■ COVER FEATURE 4
20 first three quarters of 2017, the average of 2017, compared to the rest of the year. strong, once buying normalises after the to 5 year highs of around $50/t. It’s worth supply at the end of 2018, contributing to that prices will just hold on to their recent
Vancouver f.o.b. spot price was in a $75- Changes in the phosphates sector were Lunar New Year holiday period. reflecting that for a short period in May a tight market, leaving buyers scrambling gains or whether we see further inflation;
Sulphuric acid
21 100/t range. February 2018 prices are also an important demand side contribu- There is a risk that it sounds like a 2016, spot prices at the NW European ref- for import cargoes. With relatively buoyant it seems unlikely that prices will weaken in
still around a third higher than in Febru- tion. OCP of Morocco which is extending stuck record, but we must repeat that erence were negative. copper prices, budgets for acid procure- that timeframe. n plant simulation
22 ary 2017, when the month average was its position as the world’s leading phos- the timing of various project start-ups
around $90/t. phates producer by making substantial remains the main point to watch for price
23 China was a main focus of the spike in investments in expansion and downstream direction in 2018. The Kashagan project
prices in 2017. The drop in Chinese port processing greatly increased its interna- in Kazakhstan is still in the limelight,
24 stocks to around 1.0 million tonnes was
an important feature of the price rally, but
tional sulphur activity through 2017. OCP
depends on the international sulphur mar-
not surprisingly given its potential to
substantially add to the sulphur supply Price indications
25 SULPHUR

ISSUE 375
Fig. 1: Month average spot sulphur prices, Jul 15 to Feb 18 Fig. 2: China sulphur port inventory, Mar 2014 to Feb 2018
26 $/t
million tonnes
1.8 Table 1: Recent sulphur prices, major markets
210 MARCH-APRIL 2018
27 190 1.5 Cash equivalent September October November December January
170 Sulphur, bulk ($/t)
28 1.2
Vancouver f.o.b. spot 103 170 175 145 120
150 c.fr China
0.9 Adnoc monthly contract 110 127 184 195 140
29 130
China c.fr. spot 135 185 190 150 135
0.6
110
30 90 0.3
Liquid sulphur ($/t)
Tampa f.o.b. contract 74 74 110 110 116
f.o.b. Vancouver
70 0.0 NW Europe c.fr. 117 117 123 123 136
31
Jul 15
Sep 15
Nov 15
Jan 16
Mar 16
May 16
Jul 16
Sep 16
Nov 16
Jan 17
Mar 17
May 17
Jul 17
Sep 17
Nov 17
Jan 18

Mar 14
Jun 14
Sep 14
Dec 14
Mar 15
Jun 15
Sep 15
Dec 15
Mar 16
Jun 16
Sep 16
Dec 16
Mar 17
Jun 17
Sep 17
Dec 17

Sulphuric acid ($/t)

Southbank House, Black Prince Road
32 US Gulf spot 50 60 60 60 65
London SE1 7SJ, England
Source: Integer, ICIS Source: Integer, GTIS Source: various
Tel: +44 (0)20 7793 2567
33 Fax: +44 (0)20 7793 2577

6 www.sulphurmagazine.com Sulphur 375 | March - April 2018 Sulphur 375 | March - April 2018 www.sulphurmagazine.com 7 Web: w ww.bcinsight.com
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Market outlook
ENGINEERING IS OUR PASSION ■ CONTENTS
4 Your partner when it comes to sulphuric acid.

5 Historical price trends $/tonne What’s in issue 375

6 1,000 1,000

7 Sulphur (Vancouver f.o.b.)

■ COVER FEATURE 1
$/tonne

Liquid sulphur (NW europe)

8 Sulphuric acid (ex-term Tampa) Middle East
Sulphur
9 750 750
Conference,
10
11
The Art Abu Dhabi

12 500 500 of Engineering ■ COVER FEATURE 2

13 North Africa’s
14 phosphate industry
250 250
15
■ COVER FEATURE 3
16
17 SRU combustion
0 0 challenges
18 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018

19 Source: BCInsight
■ COVER FEATURE 4
20
SULPHUR back down to a more natural level, sources of export acid in Asia have
Sulphuric acid
21 but still around 30% up on the same lower availability. In South Korea, Korea
l The timing of the start-up of key sulphur time in 2017. Increased demand from Zinc is taking 43-45 days of mainte- plant simulation
22 producing projects remains the key Ma’aden phosphates in Saudi Arabia nance downtime reducing production by
variable on the supply side. Kashagan has served to reduce export availability around 50,000 tonnes, while LS-Nikko
23 can potentially produce 1.1 million t/a from the Gulf, and continuing expan- Copper is also taking a 3 week turna-
of sulphur at full capacity. According sions at OCP in Morocco have also round. It is not clear when the PASAR
to the North Caspian Operating Com- had an effect on tightening the market operation in the Philippines will resume
24
pany (NCOC), 143,000 tonnes of sul- overall. normal exports.

25 phur have been exported by rail in the l There is likely to be relatively close con- SULPHUR

ISSUE 375
past three months. Oil production is SULPHURIC ACID nection between the markets for acid
currently said to be running at 80% of l Prices have risen in most markets at and sulphur. In our market balance
26 capacity. the start of 2018, and sulphuric acid projections, export supply from China
l Additional sulphur production from vari- markets are expected to continue to be will be required to close a supply gap. MARCH-APRIL 2018
27 ous projects in China may total up to tight during 1Q and possibly through 2Q These cargoes are only viable if produc-
1 million t/a, which may impact upon 2018. The main challenge for the sulphu- ers like Two Lions see the arbitrage
28 Chinese demand for sulphur imports, ric acid outlook is predicting availability opportunity between sulphur raw mate-
although there is no sign of this at pre- on the supply side. It remains to be seen rial costs and acid prices.
29 sent, and expectations of increased how quickly markets adjust to normal l Unless sulphur prices drop, there is
Chinese buying are continuing to sup- output from recently restarted plants no room for sulphuric acid prices to
30 port the market. in North America for example, although decline, and further inflation may be
l In the meantime, Chinese port stocks there are also several new consuming necessary. In addition, buyers like
31 have recovered considerably from projects either ramping up or scheduled OCP which have a degree of substitut-
their low point towards the end of last to come on line in North America. ability between making and buying Southbank House, Black Prince Road
32 year, and have now reached 1.4 mil- l Elsewhere, there is further sched- acid will lean toward the acid market London SE1 7SJ, England
lion tonnes, easing pressure for more uled maintenance but more impor- if its regular sulphur supplies remain Tel: +44 (0)20 7793 2567
HUGO PETERSEN GmbH Tel. +49 (611) 962-7820
33 imports and bringing sulphur prices tantly unplanned downtime. Important constrained. n
Rheingaustrasse 190-196 Fax +49 (611) 962-9099 Fax: +44 (0)20 7793 2577
65203 Wiesbaden contact@hugo-petersen.de A subsidiary of Web: w ww.bcinsight.com
8 www.sulphurmagazine.com Sulphur 375 | March - April 2018
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2 sulphur industry news

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Sulphur Industry News W E C O N V E Y Q U A L I T Y
■ CONTENTS
4
Silo and
5 ABU DHABI What’s in issue 375
Hopper Discharge
6 Adnoc to invest $3.1billion in upgrading Ruwais refinery CENTREX®
7
The Abu Dhabi National Oil Company (Adnoc) has announced its gins by introducing asset flexibility and product marketing initiatives. ■ COVER FEATURE 1
plan to invest $3.1billion to upgrade its Ruwais oil refinery in the The upgrade project will involve installation of an atmospheric
west of the Emirate. The refinery upgrade project, known as the residue de-sulphurisation (ARDS) unit which designed for upgrad-
8 Crude Flexibility Project (CFP), is intended to introduce crude pro- ing medium to heavy petroleum oils and residues to environ- Middle East
cessing flexibility and free up more Murban grade crude. The project mentally friendly transportation fuels. It is also used to partially Sulphur
9 is looking to completion in late 2022, allowing the Ruwais Refinery convert the residues to produce low-sulphur fuel oil and hydro-
West complex to process up to 420,000 bbl/d day of Upper Zakum treated feedstocks. Adnoc has awarded the engineering, procure- Conference,
10 crude (1.33% sulphur) or similar grades. Adnoc says that the project ment and construction (EPC) contract to a joint venture between Abu Dhabi

PHOTO: TOTAl
is part of its downstream refining strategy, intended to boost mar- South Korea’s Samsung Engineering and Netherlands’ CB&I. n
11
12 New gas sales agreement with Dubai minority stakes in the UAE’s onshore oil erisation unit, a hydrogen production unit, Drilling platform at South Pars. ■ COVER FEATURE 2
reserves, and in November 2017, Adnoc two PSA units, a C4 hydrogenation unit, an
Adnoc has also signed a 15-year gas sales and CNPC signed a framework agreement MTBE unit, and a sour water stripper unit Iran also says that the first offshore drilling platform in South
13 North Africa’s
agreement with the Dubai Supply Authority covering various areas of potential collabo- with sulphur recovery unit. The project is Pars Phase 14 has been successfully installed in the Gulf, with
14 for the supply of natural gas to help meet ration, including offshore opportunities and expected to be completed 41 months from the capacity to extract 500 million cfd of natural gas. As soon phosphate industry
Dubai’s energy needs. The agreement was sour gas development projects. Adnoc is the signing date. as pipeline tie-ins are complete, sour gas from Phase 14 will
signed at Adnoc’s headquarters by Sheikh focused on market expansion in China and Pierroberto Folgiero, Maire Tecnimont be transferred to South Pars 2 processing facilities before being
15 Ahmed bin Saeed Al Maktoum, Director Asia, where demand for petrochemicals chief executive officer, commented: “after injected into the Iran Gas Trunkline. Eleven wells have been Rotary Discharge Machine
General of the Dubai Supply Authority, and and plastics is forecast to double by 2040. our two strategic petrochemicals projects drilled around Platform 14A, of which eight will go on stream by type LOUISE ■ COVER FEATURE 3
16 Sultan Ahmed Al Jaber, UAE Minister of Meanwhile, BASF subsidiary Winter- in Azerbaijan, this contract enables Maire the end of February, according to the National Iranian Oil Com-
State and Adnoc Group CEO. shall, Germany’s largest oil and gas pro- Tecnimont Group to consolidate relations pany. Satellite platforms (14C and D) will be connected to the
17 As part of its 2030 growth strategy, ducer, has told Abu Dhabi English language with SOCAR in the refining business, sup- two main platforms (A and B) by 18" pipelines. Platform 14B is
SRU combustion
Adnoc plans to access undeveloped tight newspaper The National that is looking to porting their strategy of integration with the said to be “88% complete”. South Pars Phase 14 is scheduled to challenges
18 reservoirs, tap into its gas caps and partnerships in sour gas development in petrochemical business.” produce 56 million cubic meters of gas and 75,000 barrels of gas
expand sour gas production, ensuring that Abu Dhabi as it seeks to increase its Mid- condensates per year to meet domestic gas demand and sup-
19 it delivers a sustainable and economic dle East footprint. The firm has tested two IRAN ply feedstock to petrochemical units in the Pars Special Energy
gas supply to meet the UAE’s growing wells in the western sour gas field of Shu- Economic Zone in the southern Bushehr Province. The phase is ■ COVER FEATURE 4
20 demand for energy. In addition, it has com- waihat, near Ruwais, in partnership with
Qeshm Island facilities in also expected to annually produce more than 1 million tons of
pre-commissioning
menced an exploration drilling programme Adnoc and Austria’s OMV, and says that it gas condensates, 1 million tons of ethane for petrochemical units
Sulphuric acid
21 to explore for, and appraise, the potential is now “looking to play a larger role”. Hamid Bovard, the managing director and 400 tonnes of sulphur.
of individual gas deposits in tight reser- of Iranian Offshore Oil Company, says The project is under development by a consortium consisting of plant simulation
22 voirs. The Emirate is committed to spend- AZERBAIJAN that new gas processing facilities for the Industrial Projects Management of Iran, Industrial Development &
ing $109 billion over the next five years, Hengam oil and gas field on Qeshm Island Renovation Organization of Iran, Iranian Offshore Engineering and
Tecnimont awarded refinery revamp
23 and recently awarded FEED contracts for
contract
in the Gulf are in pre-commissioning and Construction Co., Iran Shipbuilding & Offshore Industries Complex
the Hail, Gasha and Dalma sour gas fields due to come on stream in the near future. Co., MAPNA Group, National Iranian Drilling Co., and Machin Sazi
to Bechtel and Technip (see Sulphur 274, Maire Tecnimont says that its subsidiaries About $87 million has been spent on the Arak. The gas sweetening facility that forms part of South Pars 13 Proven AUMUND Technology
24
Jan/Feb 2018, p11), which are expected Tecnimont SpA and KT-Kinetics Technology facilities, which will prevent the flaring of is also ready to begin operations, taking gas from South Pars 6,

25 to produce 1 billion cfd of sales gas. have been awarded the engineering pro- 2 million m3/d of associated gas. Bovard 7 and 8. • Controlled discharge SULPHUR

ISSUE 375
curement and construction (EPC) contract said that following the completion of instal-
China, Germany seeking to partner for the modernisation and reconstruction lation operations in December 2017, pre- Ilam SRU to be completed soon • Simultaneous feeding and discharge
26 sour gas developments of Heydar Aliyev Baku oil refinery in Azer- commissioning and commissioning stages Ilam refinery’s new sulphur recovery unit will be inaugurated next
Sultan Al Jaber, UAE Minister of State baijan. The contract was awarded by the have begun, and over the past two months spring, according to managing director of the National Iranian Pet- MARCH-APRIL 2018
27 • Fully automatic
and Adnoc Group CEO, met with govern- State Oil Company of Azerbaijan Republic all processing, infrastructure and utility rochemical Company Seyed Reza Norouz-zadeh. During a visit to
ment and corporate leaders in Beijing, to (SOCAR), and is worth $800 million. The units, including dehumidification, sweet- the Ilam Petrochemical Complex, Norouz-zadeh told local media
28 explore opportunities for strengthening the project scope covers the installation of ening, pipeline, tanks, boilers and com- that the SRU has made good progress in the last two years. He
• For infinitely adjustable discharge
strategic relationship between the UAE several new grassroots process units, rel- pressors, have come on stream under the said that the refinery’s revamp will be completed by the end of the capacities up to 3,000 m³/h
29 and China and deepening the partnerships evant utilities and storage, with the final pre-startup safety review. The facility will current Iranian year [ending March 2018] and the site will be fully
between Adnoc and China’s energy, chemi- aim of upgrading the refinery to be capable double gas production at Qeshm, which operational in the first quarter of the next Iranian year [2Q 2018]. In
30 cal and technology sector. China is the of processing 7.5 million t/a of crude oil, also takes gas from the Gavarzin gas field. addition to the SRU, the managing director of Persian Gulf Holding
UAE’s largest trading partner, with bilat- while meeting the quality requirements of Iran has struggled for some years to curb Adel Nejad Salim also added that 89% of other work at the Ilam
31 eral trade topping $50bn per year. In the both feed for Azerikimya’s revamped petro- the flaring of large amounts of associated Petrochemical Complex has been completed. The new project will
past year, China and the UAE have made a chemical plant and to produce Euro V qual- gas, and at the beginning of last year, have the capacity to produce 450,000 t/a of ethylene, and is also AUMUND Foerdertechnik GmbH Southbank House, Black Prince Road
32 number of joint venture investments in the ity automotive transportation fuels. Iran’s parliament passed a bill to curb the expected to become operational early next Iranian year. He noted
Saalhoffer Str. 17 • 47495 Rheinberg • Germany London SE1 7SJ, England
energy sector. In February 2017, the CNPC New process units include a naphtha flaring of natural gas to 10% or lower of its that more than 80% the refinery’s petrochemical products will be
minerals@aumund.de · www.aumund.com Tel: +44 (0)20 7793 2567
33 and China CEFC Energy were awarded splitter, a diesel hydrotreater unit, an isom- value by 2021. marketed internationally.
Fax: +44 (0)20 7793 2577

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Sulphuric Acid News
■ CONTENTS
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5 KAZAKHSTAN democratic republic of congo What’s in issue 375
6
Contract awarded for TCO acid gas
reinjection project
outotec to supply acid plants for mutoshi
7
Outotec has been awarded a e33 million contract by Shalina as environmentally sound and safe operation. ■ COVER FEATURE 1
Bonatti has been awarded the Area 51 Resources Ltd for the delivery of sulphuric acid plant technology “We really look forward to working with Shalina Resources
Pipelines contract by Tengizchevroil (TCO) to the Mutoshi project near Kolwezi in the Democratic Republic in the Mutoshi project, and are extremely pleased that we
8 for the Future Growth Project/Wellhead of Congo. Outotec’s scope includes the delivery of three skid can complete our diverse technology package for the copper Middle East
Pressure Management Project (FGP- mounted, modular sulphuric acid plants which will produce the and cobalt processing now with sulphuric acid plants. These Sulphur
9 WPMP), which will create a new gathering acid and SO2 gas required by the new Mutoshi copper-cobalt modular plants represent our latest technology, and remark-
system for transporting gas from the Ten- plant. The plant concept ensures the benefits of modular prefab- ably improve the environmental performance of the plant”, Conference,
10 giz and Korolev reservoirs to the new pro- ricated plant delivery, such as low investment, installation and said Kalle Härkki, head of Outotec’s Metals, Energy & Water Abu Dhabi
cessing facilities. Scope of work includes operation cost, increased availability and maintainability as well business. n
11 the construction and pre-commissioning of
377 km of pipelines, including the produc-

PHOTO: AzErNEWS
12 tion gathering system and high pressure glencore ups Katanga output estimate ■ COVER FEATURE 2
sour gas injection and associated utilities. Glencore says that it aims to increase
They will be partnered by local firm Mon- cobalt output by 42% in 2018 compared
13 North Africa’s
tazhspetsstroy JSC. to its figure for 2017 as production at
14 Elsewhere in Kazakhstan, the giant One of the artificial island production platforms, Kashagan. the restarted Katanga facility ramps up phosphate industry
Kashagan field has resumed production to its capacity of 11,000 t/a, represent-
after power disruptions at an onshore have licensed and supplied over 60 new ing 28% of Glancore’s total output for
15 facility cut output in mid-January. Produc-
UKRAINE
BELCO EDV wet scrubbing systems for the year. Glencore completed the first
tion from Kashagan helped drive the coun- Honeywell to provide hydrotreating FCCUs in China, preventing over 200 000 stage of the ore leach processing at the ■ COVER FEATURE 3
16 try’s crude exports higher during 2017. By catalysts for Shebelinsky refinery t/a of air pollutants from SOx and fine facility in December, producing 2,200
the end of the year Kashagan’s production particulate emissions to the atmosphere. tonnes of copper cathode by the end of
17 was running at 250,000 bbl/d, and it is Honeywell says that UkrGasVydobuvannya DuPont says that the system controls par- the year. The site had been idle since
SRU combustion
anticipated that it will reach its first phase (UGV) has begun using Honeywell UOP’s ticulate, SOx and NOx emissions in a sin- September 2015, when production was challenges
18 capacity of 370,000 bbl/d during 2018. HYT-4118 Unity hydrotreating catalyst to gle upflow tower, eliminating the need for halted because of oversupply of copper
The ramp-up at the field has also been produce ultra-low sulphur diesel fuel at separate control devices to manage differ- and cobalt on global markets. Cobalt
19 responsible for Kazakhstan over-producing the Shebelinsky refinery in Andreyevka, ent emissions. production at Glencore’s Mutanda facil-
its agreed OPSC quota. in eastern Ukraine’s Kharkov region. The ity in the DRC, dropped 3% in 2017 to ■ COVER FEATURE 4
20 catalyst removes sulphur from petroleum INDIA 27,400 tonnes due to restrictions on
NCOC says that Kashagan has
exported 140,000 tonnes of sulphur
feeds that are used to make distillate,
CPCL inaugurates refinery
sulphuric acid deliveries from the Mopani
Sulphuric acid
21 and is designed for use in low- to medium- copper mine in neighbouring Zambia dur-
In mid-February, the North Caspian Oper- pressure ultra-low sulphur diesel (ULSD) upgrade project ing 3Q 2017. Throughput restrictions at plant simulation
22 ating Company (NCOC) announced that hydrotreating units, providing high activity At the end of February, Dharmendra Prad- Mutanda resulting from heavy rainfall ear-
it had exported 143,000 tonnes of sul- and stability for longer cycle lengths with han, Minister of Petroleum and Natural lier in the year further contributed to the
23 phur from Kashagan since the first train low hydrogen consumption and ensuring Gas, inaugurated Chennai Petroleum Cor- reduction in output.
left from the Eskene West three months sulphur content of less than 10 ppm in the poration Ltd’s (CPCL) $480 million residue
24 previously. The company says that over resulting fuel. upgrade project at its Manali refinery near ZimbabWe
that period a total of 37 trains loaded with UkrGasVydobuvannya is the largest nat- Chennai. CPCL, a subsidiary of the Indian
sulphur have been exported – three each ural gas producer in Central and Eastern Oil Corportion, has added a delayed coker idcZ to sell share in chemplex SULPHUR
25
ISSUE 375
week, each with a total of 60 rail cars. The Europe accounting for 75% of natural gas with 2.2 million t/a of capacity, an 8.8 t/h The state-owned Industrial Development
trains travel to the export terminal at Ust- production in Ukraine. LPG treatment unit and a sulphur recovery Corporation of Zimbabwe (IDCZ) is seeking
26 Luga near St Petersburg as well as Port unit, as well as utilities and offsite facili- financial advisors to lead the part sale of
Kavkaz in the Caucasus. The company CHINA ties, in order to produce an extra 700,000 its subsidiary Chemplex Corporation Ltd. MARCH-APRIL 2018
27 also says that it has formed a total of
191,000 tonnes of sulphur granules since
CNOOC commissions DuPont wet
t/a of LPG and diesel, and up to 300,000
t/a of petroleum coke. The project will add
The aim according to ICDZ is to “inject
additional capital into the business, bring-
The best 2-stage solution 1 Maximize Ammonia or BTX destruction with hotter, more

for ammonia destruction

effective Zone 1 mixing
28 scrubbing system
in the business 2
production began at the gas processing value to the refinery, improving margins ing in new technology and access to wider
Optimize residence time distribution and increase
site. At capacity, the Kashagan sour oil CNOOC recently commissioned a DuPont and profitability, as well as creating 130 markets for the business.” Chemplex is throughput with rotational flow pattern
29 and gas project will be producing 4,500 BELCO ® EDV ® wet scrubbing system at its jobs, said Pradhan. It will also allow the Zimbabwe’s largest fertilizer and chemi- Whether you're faced with simple or complex combustion
configurations, realize significant process improvements
t/d of sulphur, or 1.1 million t/a. Some oil refinery on Hainan Island, China. The refinery to increase the percentage of high cals manufacturing company, and the par- with the Biasch VectorWall:"
30 liquid sulphur has been poured to block, system will allow the refinery to minimise sulphur crude it uses as feed, reducing ent company owns Dorowa Minerals and Visit us at Middle East Sulphur, Booth #29

BLASCH
but once design capacity is reached the atmospheric emissions of fine particulate costs. Sulphur production at capacity will Zimbabwe Phosphate Industries Ltd (Zim-
31 full amount will be formed and exported, and sulphur oxides (SOX) from its 1.2 mil- be 200 t/d (66,000 t/a). Phos), the country’s sole producer of sul-
Contact us today to design a VectorWall
that will fit your exact requirements.
according to NCOC, and the company is lion t/a fluid catalytic cracking unit (FCCU). Pradhan also said that CPCL will be phuric acid, as well as aluminium sulphate 800-550-5768 I +1-518-436-1263 Southbank House, Black Prince Road
32 also planning to melt and process into The system was fitted by Beijing Milestone implementing a 9 million t/a refinery and single superphosphate. It also owns blaschceramics.com London SE1 7SJ, England
granules the sulphur accumulated in the Technologies under license from DuPont expansion project at Nagapattinam at an 50% of Zimbabwe Fertiliser Company and Tel: +44 (0)20 7793 2567
33 sulphur blocks. Clean Technologies. MSTN and DuPont investment cost of $4.15 billion. n 36% of Sable Chemicals.
Fax: +44 (0)20 7793 2577

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■ CONTENTS
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5 UNITED STATES reduces time, lowers operating costs and tion capacity at the sulphuric acid plant at Foskor’s Phalaborwa operation mine. It upgraded acid plant is an Outotec double producer in the Middle East and North Africa What’s in issue 375
results in a more direct chain to battery- the site from 102,000 t/a to 182,500 t/a, has a 15 year lifespan with the capacity conversion double absorption design, and region, with 14% of Asia’s copper deposits
Itafos completes acquisition of producing end users. The company says as well as expanding carbon disulphide pro- to produce 1.35 million t/a of phosphate has a capacity of 1,000 t/d of 98.5% acid. and about 3% of global reserves.
6 Conda Phosphate Operations that it is aiming to have the pilot plant, rea- duction from 23,725 t/a to 34,675 t/a and rock concentrate. The new production projects include a
Itafos says it has completed its acquisition gent supplies, process feed material and captive power plant capacity from 25 MW to IRAN flash smelter with a capacity of 282,000 ■ COVER FEATURE 1
7 of Conda Phosphate Operations from Agrium supporting infrastructure in place by 2021, 55 MW. The expansion will take place within SERBIA t/a of copper anode; the Khatunabad
Inc., and the appointment of Ron Wilkinson once agreements are finalised. the existing 222 hectare site at Vilayat.
Copper expansions inaugurated Copper Smelter with an annual capacity
8 to the board of directors of the company. “Our commitment to advancing the
RTB Bor increases output at President Hassan Rouhani and Iran’s Minister of 200,000 t/a of copper cathode; the Middle East
Reduction in tax on phosphoric acid Veliki Krivelj
The Conda Phosphate Operations, located SiLeach process to an industrial scale is a of Industries, Mining and Trade Mohammad Sarcheshmeh copper plant’s new conver- Sulphur
9 in Conda, Idaho, includes phosphate pro- critical element in the research and devel- The Indian government has reduced the RTB Bor says that production of cop- Shariatmadari have inaugurated a series of tor furnaces’ gas discharge system and
duction facilities and adjacent phosphate opment required to bring a superior process rate of Goods and Services Tax (GST) on per ore at its Veliki Krivelj open pit mine projects in the Iranian copper industry under the expansion of Sarcheshmeh’s sulphu- Conference,
10 mineral rights, and produces approximately into the lithium industry,” he explained. phosphoric acid from 18% to 12%. The increased by 40% year-on-year to 855,000 the auspices of the Iranian Mines and Min- ric acid plant capacity to 300,000 t/a. Abu Dhabi
540,000 t/a of mono-ammonium phos- move follows representations from the tonnes in January. The company aims to ing Industries Development and Renovation Sarcheshmeh is the world’s second larg-
11 phate (MAP), super phosphoric acid, mer- CHINA Indian fertilizer industry that the 18% tax produce 830- 900,000 tonnes per month Organisation. NICICO is the leading copper est open-pit copper mine. n
chant grade phosphoric acid and specialty on acid inputs to diammonium phosphate of copper ore this year, close to the mine’s
Start-up for world’s largest WSA plant ■ COVER FEATURE 2
12 products for the North American fertilizer (DAP) production (India imports most of its maximum capacity. State owned RTB Bor
market. Agrium agreed to sell Conda for The Bestgrand Chemical Group has phosphoric acid requirement) was too high completed an upgrade of its smelter acid
$100 million just prior to its merger with announced the successful start-up of its compared to the 5% GST tax on fertilizer plant in November 2017 which tripled
13 North Africa’s
PotashCorp to form Nutrien in order to ease wet gas sulphuric acid (WSA) plant in China. production, leading to working capital being capacity from 50,000 m3 per hour of sul-
14 regulatory concerns and allow the merger The plant will be the world’s largest, with a tied up in unused input tax credits and cash phur dioxide (SO2) to 155,000 m3/hour. phosphate industry
to proceed. It also sold its North Bend Ohio production capacity of 300,000 tonnes of flow issues for fertilizer producers. RTB Bor will use the additional sulphuric
nitric acid operations to Trammo Nitrogen sulphuric acid per year. The plant will treat acid for fertilizer production.
15 Products Inc (formerly Transammonia). 131,000 t/a of acid gas over-the-fence from CANADA
Itafos says that Conda’s new director the neighbouring world-scale refinery oper-
Nutrien to stop buying phosphate
AUSTRALIA ■ COVER FEATURE 3
16 Ron Wilkinson is a former Agrium execu- ated by a joint venture between CNOOC
tive with a career spanning 40 years in the (China National Offshore Oil Corporation) and from Western Sahara BHP ramping up production at
17 fertilizer industry. He served as senior vice Shell in Huizhou City, China. In deciding to go Newly merged Agrium and PotashCorp Olympic Dam SRU combustion
president and president of Agrium’s Whole- the WSA route, Bestgrand Chemical Group venture Nutrien says that it intends to BHP is ramping up operations at Olympic challenges
18 sale Business Unit from 2004 to 2015, says that it has focused on the environ- stop buying phosphate rock from Western Dam to full capacity in 1Q 2018, following
responsible for manufacturing operations mental benefits as well as the high energy Sahara, according to Chuck Magro, Nutrien a $350 million smelter upgrade project last
19 for 12 production sites, along with the efficiency and heat recovery of the process. president and CEO, speaking at an investor August, according to the company. Smelt-
AdvaSulf
■ COVER FEATURE 4
TM

associated supply chain, sales, marketing The company predicts that it will reduce car- conference in British Columbia. Agrium’s ing operations resumed late last year,
20 and distribution. bon dioxide emissions by 220,000 t/a and import contract with Moroccan phosphate BHP says, with the first anode cast from
“Itafos continues to deliver on its stra- reduce sulphur dioxide (SO2) emissions to major OCP will end during 2018, he said, the flash furnace in December. Operations HySWEET® Sulphuric acid
21 tegic objective of becoming a leading global a level 50% lower than that required of the ending imports into Canada. The com- will continue to ramp up to full capacity in
COSWEET
plant simulation
TM

player in the phosphate fertilizer industry,” sulphuric acid industry. The process converts pany is still considering what to do with first quarter of 2018. BHP has also under-
22 said Brian Zatarain, chief executive officer more than 99.9% of the sulphur in the off- its import contract via PotashCorp, which taken major upgrade works on the refinery,
SweetSulf TM

of Itafos. “We are pleased to have closed gases into commercial grade sulphuric acid. takes rock into Baton Rouge, Louisiana. concentrator, and other key infrastructure
23 this transformative transaction and look The technology was licensed from Haldor and site technology at Olympic Dam. Cop- Sprex ®

forward to working with Mr. Wilkinson who Topsoe, which has licensed 68 WSA plants SOUTH AFRICA per dropped from 203,000 tonnes in
further strengthens the leadership of the in China since 2000, of which 54 are already the 2015/16 financial year to 166,000 AdvAmine
24
TM

company with extensive industry experi- on stream, and 14 are under construction. Restart for phosphate operation tonnes in 2016/17, and is expected to be

25 ence and a successful track record of driv- Phosphate miner Kropz SA says that it will 150,000 t/a in 2017/18 before increas- SULPHUR

ISSUE 375
ing profitable growth.” INDIA re-start mining at its Elandsfontein phos- ing to 215,000 t/a in 2018/19 and up to
phate project before the end of 2018. The 280,000 t/a by 2022/23, with a concomi-
26 AUSTRALIA Grasim to expand acid production project, on the west coast of South Africa, tant increase in sulphuric acid production
MARCH-APRIL 2018
27 Lithium Australia to pilot acid
Grasim Industries, part of the Aditya Birla was commissioned in 2017 but a combina- to 840,000 t/a. A UNIQUE TASTE OF SWEET FOR YOUR GAS
Group, has received clearance from the tion of low phosphate prices, delays in gain-
leach plant Environment Ministry for an expansion at its ing water permits and operating issues led Port Pirie restarts after upgrade
28 Lithium Australia says that it has com- Vilayat fibres production unit. The $400 mil- to the decision to place the facility on care Nyrstar has re-started its smelter at Port
50 YEARS OF EXPERIENCE IN GAS SWEETENING AND
mitted to building a large-scale pilot plant lion expansion project will increase produc- and maintenance in September. According Pirie, north of Adelaide, after a A$600 mil-
SULPHUR RECOVERY PROCESSES
29 in order to commercialise its new SiLe- tion at the viscose stable fibre (VSF) plant to company CEO Ian Harebottle, return- lion investment to cut pollution and ensure
ach technology, following the results of at Vilayat, one of four such plants that the ing the facility to production will require a its long-term viability. The upgrades include With its unique and complete proprietary technologies portfolio,
30 a positive preliminary feasibility study in company operates in India, two of which are revised plant design which can accommo- moving to a completely enclosed furnace PROSERNAT offers optimized solutions to bring on specs any
type of gas contaminated with CO2, H2S, COS and organic
July 2017. SiLeach is a fluoride and sul- sited in Gujarat state. The company plans date the ore body, and raising new capital. design to capture dust and sulphur dioxide
sulphur species, while producing sulphur with the most stringent
31 phuric acid-based leach that is focused on to increase the VSF capacity of VSF from The latter may come from South Africa’s emissions which would result in a mark-
emissions standards.
optimising water balance and potassium 127,750 t/a 255,500 t/a, as well as set- Industrial Development Corporation, private edly improved environmental footprint, Southbank House, Black Prince Road
32 sulphate production, eliminating the need ting up a facility for solvent spun cellulosic equity or possibly a public stock offering. according to the company. Port Pirie pro- www.prosernat.com London SE1 7SJ, England
for the usual lithium carbonate roasting fibre with a production capacity of 36,500 Elandsfontein is the second largest duced 59,000 tonnes of sulphuric acid Tel: +44 (0)20 7793 2567
33 process. Lithium Australia says that this t/a. This will also entail expanding produc- phosphate deposit in South Africa, after in 2016, according to Nystar figures. The
Fax: +44 (0)20 7793 2577

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The Sulphur Institute (TSI) has announced global industry management and design The Mosaic Company says that Rich What’s in issue 375
the selection of Sarah Amirie as the organi- engineering teams. Development efforts will Mack will step down from his position as
sation’s new director of operations. In this focus on bringing new products to market executive vice president and chief financial
6 role, Ms. Amirie will oversee member rela- that will help industries meet ever evolving officer, and leave the company in May of

7
tions, third party vendor services, and office quality requirements coupled with tighter 2018. Tony Brausen will serve as senior ■ COVER FEATURE 1
management. Robert McBride, TSI president emissions controls and reduced energy con- vice president – finance and interim CFO,
and CEO, remarked: “we look forward to hav- sumption targets. effective immediately, until the position
8 ing Sarah’s experience, which will enhance “We are pleased to have Chris join is filled permanently. He will also serve Middle East
TSI programs and operations.” Ms. Amirie AMETEK Land,” said Justin Smith, manag- as the Company’s designated principal Sulphur
9 has previously worked as an executive ing director. “He has extensive experience accounting officer. Tony has led Mosaic’s
assistant, treasury analyst, and software in product development and management accounting, financial analysis and report- Whether you are looking for sulfur recovery Conference,
10 development technician throughout several gained across a number of industries that ing, treasury, tax, information technology Abu Dhabi
departments in the federal government prior will be invaluable to this role in fast track- and business unit finance teams. technology in compliance with your local
11 to joining TSI. She has a bachelor’s degree ing the development of market-focused “On behalf of Mosaic’s Board of Direc-
from Marymount University and a Certificate and customer-led new products from con- tors and our Senior Leadership Team, I environmental regulations, the removal of
12 in Computer Software Engineering from cept to global brand leadership.” would like to thank Rich for his 24 years ■ COVER FEATURE 2
George Washington University. As a result of Mr. Leonard’s appointment, of dedicated service and his contribution sulfur components from a sour gas stream
13 AMETEK Land has appointed Chris-
topher Leonard to the role of Director of
Dr. Peter Drögmöller takes up the new posi-
tion of Director of Innovation and Technol-
to many aspects of the company, from his
Cargill years prior to Mosaic’s formation through amine treating or removal of H2S and North Africa’s
14 Development and Product Management. ogy. Dr. Drögmöller has a wealth of industry through the very promising Vale Fertilizantes
NH3 in sour water stripping, Jacobs Comprimo® phosphate industry
Mr. Leonard has over 20 years of experi- and product knowledge in industrial infrared acquisition,” said Joc O’Rourke, President

15
ence in mechanical and process engineering
gained in the oil and gas, chemical, energy,
camera systems for challenging applications
and harsh environments. Dr. Drögmöller will
and CEO. “Rich advanced many strategic
initiatives for Mosaic and conducted him-
Sulfur Solutions provides you the necessary
and mining sectors. He has held roles in continue to develop AMETEK Land’s innova- self and led the CFO organization with the
technology, expertise and support. ■ COVER FEATURE 3
16 industrial application engineering and prod- tion relationships with strategic partners, highest ethical standards and integrity. Rich
uct commercialization of instrumentation universities and research centres globally to has a broad network and is well respected
17 from concept to market-leading brands and ensure that the company stays at the fore- at Mosaic and by outside constituents. We
SRU combustion
has worked for a variety of global industry front of technology and remains the number wish him all the best in his future endeav- challenges
18 heavyweights, including Hydratight, Bridon one choice for temperature measurement ors. We are pleased to have Tony serve as
International and most recently Oxford Flow. and emissions monitoring instrumentation interim CFO, and he will continue in an advi-
19 In his new role, he will head the company’s around the world. sory capacity to the permanent CFO. n
■ COVER FEATURE 4
20
21 Calendar 2018 „ Global leader in Gas Treating and Sulfur Recovery
Sulphuric acid
plant simulation
22 MARCH 30-MAy 4 18-20 Technologies
Sulphur Experts Technical Training Course, 86th IFA Annual Conference,
12-14 „ More than 500 units licensed during the last 40 years
KEMAH, Texas, USA BERLIN, Germany
23 Phosphates 2017, MARRAKESH, Morocco
Contact: Sulphur Experts Training Coordinator Contact: IFA Conference Service, „ Customers include major refineries, gas plants, and
Contact: CRU Events
Tel: +44 20 7903 2167 Tel: + 1 281 336 0848 28 rue Marbeuf, 75008 Paris, France. coal gasification units, power & chemical plants
24 Email: Seminars@SulphurExperts.com Tel: +33 1 53 93 05 00
Email: conferences@crugroup.com
Email: ifa@fertilizer.org
around the world
25 18-21 JUNE „ Total Project Solutions: Technology Selection & SULPHUR

ISSUE 375
Middle East Sulphur, ABU DHABI, UAE JULY
Contact: CRU Events 6-7 Licensing, Technical Studies, Basic Design, FEED,
26 Tel: +44 20 7903 2167 European Sulphuric Acid Association General
T.B.C.
Detailed Design, EP, EPCm & Modular Supply
Email: conferences@crugroup.com Assembly, TALLINN, Estonia
Amine Treating and Sour Water Stripping MARCH-APRIL 2018
27 Course, HOUSTON, Texas, USA „ Centers of Expertise in The Hague (the Netherlands)
19-23 Contact: Patricia de Hertogh, CEFIC,
Sulphur Experts Technical Training Course, Avenue E. van Nieuwenhuyse,
Contact: Brimstone STS Ltd and Calgary (Canada)
28 KUALA LUMPUR, Malaysia 4/2, B-1160 Brussels, Belgium
Tel: +1 909 597 3249
Email: mike.anderson@brimstone-sts.com
Contact: Sulphur Experts Training Coordinator Tel: +32 (0)2 676 7253
Web: www.brimstone-sts.com
29 Tel: + 1 281 336 0848 Email: pdh@cefic.be
Email: Seminars@SulphurExperts.com Web: www.sulphuric-acid.eu NOVEMBER
30 APRIL 8-9 5-8
29-MAy 3 42nd AIChE Annual Clearwater Conference Sulphur 2018 Conference and Exhibition,
31 SOGAT 2018, ABU DHABI, UAE 2017, CLEARWATER, Florida GOTHENBURG, Sweden
Contact: Dr Nick Coles, Dome Exhibitions Contact: Perry Alonso, Contact: CRU Events Southbank House, Black Prince Road
32 Tel: +971 2 674 4040 AIChE Central Florida Section Tel: +44 20 7903 2167 London SE1 7SJ, England
Email: nick@domeexhibitions.com Email: vice-chair@aiche-cf.org Email: conferences@crugroup.com Comprimo® Sulfur Solutions is part of Jacobs, one of the world’s largest and most diverse providers of Tel: +44 (0)20 7793 2567
33 technical professional and construction services Fax: +44 (0)20 7793 2577

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be completed next year. The ultimate aim expansion, taking Bahrain from its current tional banking restrictions continue to What’s in issue 375

The centre of
is to produce collectively 1 billion scf/d of 150-160,000 t/a or so of production to make getting money into and out of Iran
sales gas in the second half of the next double that at 320,000 t/a. extremely difficult.
6 decade in order to provide sufficient for

7
electricity generation for another two mil- Iran Kuwait ■ COVER FEATURE 1
lion new homes, at an estimated cost of

the sulphur
$20 billion, including construction of up to Iran produces sulphur from four refiner- Kuwait’s sulphur production runs at about
8 11 offshore islands for recovery and pro- ies, at Tehran, Tabriz, Bandar Abbas, 800,000 t/a, with refining providing most Middle East
cessing sites – the water is relatively shal- and Esfahan, as well as the Razi and of this. Kuwait has had ambitious plans Sulphur
9 low (about 15 metres depth) but includes Kharg petrochemical complexes, but as to increase its oil and gas production for
Conference,

world?
an important marine protection zone. with many of the countries of the region, many years, most notably Project Kuwait,
10 Adnoc is reportedly close to awarding five most of its sulphur production has come which was to increase oil production to 4 Abu Dhabi
technology licensor contracts, covering gas from natural gas processing. There are million bbl/d by 2020. While there has
11 treatment; a sulphur recovery unit (SRU); three sour gas processing complexes – at been some improvement from previous
natural gas liquids; condensates recovery Khangiran (Hasheminajad) near Mashhad figures (actual production in 2016 was
12 and hydrogen generation. in the northeast of the country, at Ilam 3.1 million bbl/d), laws preventing foreign ■ COVER FEATURE 2
Finally, there is the Bab sour gas pro- in the west near the Iraqi border, and at ownership of oil facilities and bureaucratic
ject, from which Shell pulled out in 2016. Assaluyeh, where the gas from South Pars delays have pushed many of these projects
13 North Africa’s
Bab is an onshore field 150 km southwest is brought ashore, and Assaluyeh and back. The consequence has been a grow-
14 of Abu Dhabi city. The original plan was a Khangiran are the two largest of these. ing shortfall in natural gas to meet local phosphate industry

PHOTO: AL HOSN GAS

$10 billion mirror of Shah, processing 1 Total output ran at about 1.7 million t/a demand, and consumption has moved
billion scf/d of gas to generate 500 million from a capacity of 2.2 million t/a, and has ahead of production. Now, as well as giving
15 scf/d of sales gas and probably a similar slowly increased as new phases of South the go-ahead to a new LNG import termi-
amount of sulphur by 2020. While Shell’s Pars come on-stream. nal, the Kuwait Oil Co has launched a new ■ COVER FEATURE 3
16 exit has dented the project, Adnoc insists The South Pars project has proceeded Upstream Strategic Objective 2030 which
that it is continuing to pursue it. in 28 development phases involving gas aims to maximise production from existing
17 Tapping of sour gas fields and continuing refinery expansions Above: Sulphur This rapid expansion in sulphur pro- production and associated onshore facili- associated gas fields, as well as tapping
SRU combustion
will see the Middle East continue to become increasingly
storage at the Shah duction has turned Adnoc into the world’s ties, including gas and condensate pro- into sour, non-associated gas fields, espe- challenges
18 project, Abu Dhabi. largest exporter of sulphur and as a con- cessing and downstream petrochemical cially in the northern, Jurassic formation.
dominant on the sulphur export scene over the next few years. sequence, Adnoc has, albeit perhaps of works. The final phase, the long-delayed Engineering, procurement and construc-
19 necessity, decided to see sulphur as a Phase 11, is now likely to be completed tion companies have been invited to sub-
strategic asset rather than as a problem. in 2021-22, with a $4.8 billion agreement mit bids before the end of February 2018 ■ COVER FEATURE 4
20 Most recently, Adnoc has signed a by Total and China National Petroleum Cor- to lift non-associated gas production from

O Sulphuric acid
ver the next five years, annual sulphur production in Abu Dhabi mainly Development project, which gathers gas sulphur supply deal with Morocco’s OCP, poration signed in late 2016 with Iran’s its current 180 million cfd to 510 million
21 global sulphur production is fore- comes from Ruwais East and West (total from a number of fields to a processing running to 2025, with a steady increment Petropars. Sulphur production could rise cfd, along with 200,000 bbl/d of light oil.
cast to increase by about 10 mil- 800,000 bbl/d capacity – the 417,000 site at Habshan. The Habshan V site cur- in supply from Abu Dhabi to Morocco over another 500-600,000 t/a over that period. The tender follows two contracts signed plant simulation
22 lion tonnes, and more than 50% of this bbl/d expansion started up in 2015). Sul- rently processes 2.3 billion scf/d of gas to that time. Morocco imported 2 million t/a Iran says that it also has plans to in 2017 worth more than $1 billion with
growth will be in the Middle East. New phur recovery is a relatively modest 30 t/d produce 1.1 billion scf/d of sales gas and of sulphur from Adnoc during 2016. revamp its ageing oil refineries – the coun- Schlumberger for the development of oil
23 refinery capacity and continuing expansions at Ruwais. 5,200 t/d of sulphur, and this year it is try has suffered from a chronic shortage of and gas facilities at the East Raudhatain
of sour gas production in order to provide Abu Dhabi’s continuing move to mon- due to be expanded by a further 400 mil- Bahrain refining capacity and has actually often had field, as part of the second phase of the
power to rapidly increasing populations will etise its sour gas resources, conversely, lion scf/d with tie-ins from the Bab North to resort to importing gasoline even while Jurassic gas project. Black&Veatch has
24
drive this increase, and in spite of some has generated extremely large volumes East development. Bahrain’s sulphur production comes from it was exporting oil. These would obviously been awarded the licensing, FEED, opera-

25 increases in phosphate processing which of sulphur. Abu Dhabi continues to rap- The flagship Shah project, developed by refining, at the Bahrain Petroleum Com- also be a major boost to sulphur capacity tion, and maintenance support services for SULPHUR

ISSUE 375
will lead to new demand in Saudi Arabia, idly expand – the Emirate’s population Al Hosn Gas, a 60-40 partnership between pany (Bapco). Bapco’s ageing refinery at – Iran currently mainly produces gasoline the gas processing section at Jurassic Gas
most of this extra sulphur seems destined reached an estimated 3 million in 2016, the Abu Dhabi National Oil Co (Adnoc) and Sitra is due for an expansion over the next to Euro-4 standards at Shazand Arak, Isfa- Facility 1, including three parallel, identi-
26 to find its way onto global markets. and is continuing to grow at around 5-8% Occidental Petroleum, and which began few years. A consortium of TechnipFMC, han and Tabriz refineries, and Euro-3 at the cal 135 t/d SRUs with dedicated tail gas
per year, which would take it to more than operations in 2015, is also due for a 50% Samsung and Tecnicas Reunidas has others, but there is an upgrade in progress treatment units. Siirtec Nigi is designing MARCH-APRIL 2018
27
Abu Dhabi 6 million people by 2030. The country’s expansion to 1.5 billion scf/d, and plans won the $4.2 billion EPC and commission- at Bandar Abbas and Lavan. NIOC puts Ira- and supplying two modular SRUs for the
Economic Vision 2030 plan envisages a have been floated for this to ultimately ing contract to expand the refinery from nian refining capacity at 2.1 million bbl/d, Sabriya and East Raudhatain Gas Treat-
28 Abu Dhabi has been at the forefront of huge increase in natural gas production to be doubled. The 50% expansion, which 267,000 bbl/d to 360,000 bbl/d by 2022. but the government aims to increase this ment Plants, each with a capacity of 200
new sulphur production in the region over feed electricity generation in order to cope is believed to be looking towards a 5-year With Bahrain’s own oil reserves running to 3.4 million bbl/d by 2025. t/d of liquid sulphur.
29 the past few years, with production rising with these new people. Some 98% of Abu timescale (ca 2022) could see sulphur pro- down, the Bapco refinery is primarily sup- However, various uncertainties remain More new sulphur production from
to 6 million t/a in early 2017 due to new Dhabi’s electricity comes from natural gas- duction at Shah increase to 14,500 t/d. plied by pipeline from neighbouring Saudi over all of these projects, not least Kuwait is projected to come from the expan-
30 production from the Habshan and Shah based generation, and the Emirate already In the meantime, work continues on Arabia, and a key component of the expan- because of the political climate in the sion of refining capacity in the country via
processing plants. While there are two imports 2 bcf/d of gas along the Dolphin offshore sour gas projects, at Hail, 100km sion will be the associated expansion in region which has seen Iran pitted against the Clean Fuels Project, which involves the
31 refineries in the Emirate – one at Ruwais Pipeline from Qatar. west of Abu Dhabi city, Ghasha and Dalma pipeline capacity from the Abqaiq process- Saudi Arabia in a series of proxy conflicts, upgrade and integration of the Mina Abdulla
and a small and relatively simple process- There is a $110 billion plan for devel- – the so-called North West Area. Bechtel ing hub in Saudi Arabia from 230,000 in Yemen, Syria and elsewhere. Israel (MAB) and Mina Al Ahmadi (MAA) refineries, Southbank House, Black Prince Road
32 ing facility at Abu Dhabi itself, most of oping new gas production and infrastruc- (UK) was awarded the Hail & Ghasha front bbl/d to 350,000 bbl/d, due in 2018. and the Trump administration’s concerns increasing the combined capacity of the London SE1 7SJ, England
this sulphur production has come from ture. Projects on the go currently include end engineering and design contract and A further 500 t/d of additional sulphur about the Iran nuclear deal could see refineries from 736,000 bbl/d to 800,000 Tel: +44 (0)20 7793 2567
33 processing of sour gas reserves. Refinery continuing expansion of the Integrated Gas TechnipFMC the Dalma contract, both to recovery capacity forms part of the refinery American sanctions return, and interna- bbl/d, and lowering the sulphur content of
Fax: +44 (0)20 7793 2577

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2 MIDDLE EAST

3
4 Others simply sell a product – ■ CONTENTS

we offer a solution. What’s in issue 375

petroleum products. There is also a new Table 1: New sulphur production from the Middle East, 2217-2222, million t/a
5 refinery being built at Az Zour, which will
replace the Shuaiba Refinery. The Kuwait
6 National Petroleum Company (KNPC) says
Country Refining Sour gas Total
Abu Dhabi 0.1 0.5 0.6
7
the first phase of its liquid sulphur treat-
Bahrain 0.15 0 0.15
■ COVER FEATURE 1
ment project at Mina al-Ahmadi has been

A control and shut off technique you can rely on.

OHL Gutermuth
completed. The facility includes four storage Iran 0.1 0.55 0.65
8 tanks for liquid sulphur, with a total capacity Kuwait 1.6 0.25 1.85
Middle East
of 18,000 tonnes, as well as 5,000 t/d of
Qatar 0 0.7 0.7 Sulphur
9 granulation facilities and a warehouse with
a capacity of 145,000 tonnes of solid sul- Saudi Arabia 0.5 2.1 2.6 Conference,
10 phur, together with a jetty for loading and Total 2.45 4.1 6.55 Abu Dhabi
export of the sulphur – Kuwait’s first facility
Source: BCInsight
11 for production, storage and export of solid
sulphur, and will handle liquid sulphur from
12 the KNPC Clean Fuels Project and facilities ■ COVER FEATURE 2
of the Kuwait Oil Co. The Clean Fuels Pro- Qatargas Common Sulphur Project Expan- On the refinery side, another com-
ject is due to be completed this year. Mean- sion at Ras Laffan. Enersul will supply two ponent of Saudi Arabia’s Vision 2030
13 North Africa’s
while Enersul is supplying four granulators 1,250 t/d GXM1™ sulphur granulation units strategy is greater processing of crude
14 for the Az Zour project, each with a capacity in the second quarter of 2018, for a total domestically for export of finished prod- phosphate industry
of 1,250 t/d, which will be delivered in the additional forming capacity of 825,000 ucts. Saudi Aramco is in the process of
first quarter of 2018. Overall completion of t/a. Qatar has also shifted responsibil- constructing a wholly-owned refinery at
15 Al Zour phase 2 is set for May 2019. ity for sales and marketing of its sulphur Jizan with a capacity of 400,000 bbl/d,
to the Qatar Chemical and Petrochemical which will be completed by 2018, and ■ COVER FEATURE 3
16
Qatar Marketing and Distribution Company (Mun- which is liable to come to full operation in
tajat) as from January 1st 2018. 2019. Sulphur output at Jizan is expected
17 Qarar mainly processes slightly sour gas to be 400,000 t/a, and another 100,000
SRU combustion
from the North Field at its huge LNG and Saudi Arabia t/a will come from an expansion at Rabigh. challenges
18 GTL complex at Ras Laffan, on the north-

19
ern tip of the Qatar peninsula. Sulphur In common with other countries in the Regional sulphur balance
recovered from these facilities is sent to region, such as Abu Dhabi and Kuwait,
the Common Sulphur Facility where it is Saudi Arabia is looking to expand non- Table 1 shows the effect of all of these ■ COVER FEATURE 4
20 formed and exported. Total sulphur recov- associated gas production in order to new additions to sulphur capacity. If all
ery and forming capacity at Ras Laffan is generate more electricity, and as with Abu of these come to pass without significant
Sulphuric acid
21 approximately 3.5 million t/a, with actual Dhabi and Kuwait, this has also meant tap- delays, then there is the potential for an
production just over 2 million t/a, repre- ping into sour gas reservoirs. A major pro- extra 6.5 million t/a of extra sulphur to plant simulation
22 senting most of Qatar’s 2.3 million t/a of gramme of sour gas development is now come from the Middle East by 2022, and
production. Qatar, already the world’s larg- under way, with additional gas output from even a conservative forecast would be in
23 est LNG exporter, has plans to expand its both onshore and offshore sour gas fields the region of 5 million t/a. Set against
current LNG production and export from 77 and several gas processing plants which this is the ramping up of the Wa’ad al Sha- OHL Gutermuth switching- and metal seated butterfly valves are
million t/a to 100 million t/a by 2022 after are generating additional tonnages of sul- mal phosphate project in Saudi Arabia,
24 specified and accepted internationally, as the ultimate in reactor
a moratorium on new gas-based projects phur. The Kursaniyah gas plant started up which will consume an additional 1.5 mil- switching valves for Sulphur Tail Gas Clean-up Processes.
25 that nearly saw Qatar overtaken by other in 2012 and takes gas from the offshore lion t/a of sulphur to manufacture phos- SULPHUR

ISSUE 375
LNG producers such as Australia. Most of Karan field to produce about 300,000 t/a phoric acid, and the potential for a third We offer an exceptionally rugged valve with a different concept. Optimize your
Qatar’s new gas and hence sulphur is due of sulphur. Wasit, located north of Jubail, project – although Ma’aden said recently production sequences, using a switching valve, which is providing an extremely
26 to come from the RasGas Barzan LNG pro- takes gas from the offshore Arabiyah and that the target date of the latter is not low leakage rate, with a minimum pressure drop, as well as superb reliability.
ject, but an undersea gas leak discovered Hasbah sour non-associated gas fields until 2024, so this is unlikely to provide Available in sizes ranging from 1” through 80” with fabricated or cast steel MARCH-APRIL 2018
27 in October 2016 has delayed commission- and began operations in February 2016. any additional demand during the next five body and heating jacket.
ing of the first phase of the project, and At capacity, which should be reached this years. Any other demand for sulphur in the
28 current estimates put completion at the year, it will process 2.5 billion scf/d of region is likely to be incremental at best.
Literally dozens of plants and refineries, worldwide, using SULFREEN,
end of 2018 or start of 2019. Once the sour gas to produce 1.7 billion scf/d of Thus somewhere between 3.5 and 5 mil- MCRC and CBA processes, among others, have OHL Gutermuth
29 second phase of the project is on-stream, sales gas and 1.6 million t/a of sulphur. lion t/a of new sulphur is likely to be com- hot gas switching valves and butterfly valves in their system
and LNG production rises to 100 million Other new gas plants include Fadhili, ing from the Middle East by 2022. Adnoc „made in Altenstadt/Germany”.
30 t/a, sulphur production could rise as high designed to process additional gas has already indicated that it will be trying It’s good to know where to find OHL Gutermuth
as 3.5 million t/a in Qatar. from the Kursaniyah and Hasbah sour to sell much of its additional sulphur into
perfect valve technology. Industrial Valves GmbH
31 The gas expansions will all necessitate gas fields. Target production has been Morocco via its deal with OCP, but the fate
an increase in Qatar’s sulphur output. increased to 2.5 billion scf/d, and sulphur of the rest remains uncertain. Kuwait’s Southbank House, Black Prince Road
32 Enersul says that it has been awarded production at capacity is expected to be recent investment in granulation capacity Helmershäuser Strasse 9+12 · 63674 Altenstadt/Germany London SE1 7SJ, England
an equipment supply contract from Doha 4,000 t/d (1.3 million t/a). Fadhili is due indicates that it is definitely looking to for- Phone +49 6047.8006-0 · Fax +49 6047.8006-29 · www.ohl-gutermuth.de · og@ohl-gutermuth.de Tel: +44 (0)20 7793 2567
33 Petroleum Construction Co. Ltd. for the for completion in 2019. eign markets for its sulphur. n
Fax: +44 (0)20 7793 2577

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2 phosphates phosphates

3
■ CONTENTS
4
5
finished phosphate production, as meas- What’s in issue 375
The Jorf Lasfar phosphate hub, Morocco. ured by its share of phosphoric acid manu-
facture, and Morocco (and South Africa)
6 represent the lion’s share of this.

7
This figure used to be even smaller, ■ COVER FEATURE 1

North
before the beginning of Morocco’s cur-
rent push to capture more of the value
8 chain by developing phosphate processing Middle East
industries and phosphate fertilizer produc- Sulphur
9

PHOTO: OCP
tion domestically, and Morocco’s success

African
in doing so has encouraged other major Conference,
10 reserve holders like Tunisia, Algeria and Abu Dhabi
Egypt to see if they can follow suit. As DAP production in Morocco.
11 the continent is relatively poor in terms

phosphates
of sulphur production – there is no sour an extra 14 million t/a of mine capacity t/a at the start of 2022. In the meantime,
12 gas production and what refineries there is being added to take capacity to 38 mil- the third and final projected phase of the ■ COVER FEATURE 2
are are often relatively simple and produce lion t/a. OCP has instituted beneficiation Jorf Lasfar Phosphate Hub development,

PHOTO: OCP
little sulphur as by-product – this means plants and built two gravity-driven slurry to begin in 2019 and running to 2025,
13 North Africa’s
that North Africa is likely to represent an pipelines to take phosphate concentrate will be to add another six 1.0 million t/a
14 increasingly important slice of demand for from the mines to the coastal processing MAP/DAP complexes to bring OCP’s total phosphate industry
the world’s sulphur. plants, the largest cluster of which is at production of finished fertilizers from 12
the massive Jorf Lasfar Phosphate Hub million t/a to 18 million t/a, and bringing
15 North Africa continues to be a major growth area for sulphur Table 1: Global phosphate reserves, Morocco (JLPH) complex. According to the company, phosphoric acid capacity to over 11 million
demand. As well as the continuing expansion of OCP’s billion tonnes P2O5 the 38 million t/a capacity slurry pipeline t/a. New processing lines are also planned ■ COVER FEATURE 3
16 Morocco is the dominant nation in the connecting Khouribga to Jorf Lasfar has for the port of Safi to handle later expan-
phosphate processing capacity there are also new projects in Country Reserves Percentage world’s phosphate industry. But although reduced phosphate concentrate cash cost sions of mining from Gantour.
17 SRU combustion
Tunisia and Egypt, and potentially also Algeria. Morocco 50.0 75% as noted above it probably has something to around $20/tonne, making OCP the low-
like 75% of the world’s phosphates under est-cash cost rock producer globally. Sulphur enhanced fertilizers challenges
18 China 3.7 6%
its control, it produces only 13% of the
Algeria 2.2 3%
world’s phosphate rock, and only 11% of Jorf Lasfar As well as increasing the volume of produc-

N
19 orth Africa is to the world’s phos- try, but more important still is the potential Syria 1.8 3% finished phosphates, and the Moroccan tion of its basic mono- and di-ammonium
phate industry what the Middle that it holds for future development. Jordan 1.5 2% state has taken a long term strategic deci- Jorf Lasfar is where most of the downstream phosphates and triple superphosphate ■ COVER FEATURE 4
20 East is to the oil industry – while Table 2 shows Africa’s current phos- South Africa 1.5 2% sion to change this. Morocco’s phosphate investment is taking place. In cooperation (TSP), OCP is also attempting to branch
it is an important producer and exporter, phate production. Africa as a continent is
United States 1.4 2%
business is almost entirely in the hands with Jacobs Engineering via a joint venture out into more speciality fertilizers with a
Sulphuric acid
21 it is even more important because of the responsible for 20% of the world’s phos- of state-owned Office Chérefien des Phos- company formed in 2010, OCP has built an broader product offering via what it calls
share of global reserves that it contains. phate rock production, and 90% of that Russia 1.3 2% phates (OCP). OCP represents a major sec- additional four integrated DAP/MAP plants, Performance Phosphate Products, includ- plant simulation
22 Global phosphate reserves are not as well is in North Africa – the only other major Peru 0.8 1% tor of the country’s economy, employing each with a capacity of just over 1.0 mil- ing soluble fertilizers, animals feeds, micro-
characterised as oil, and subject to some- African phosphate producing countries are Saudi Arabia 0.8 1% 20,000 people and accounting for 25% of lion t/a, and each consuming 500,000 nutrient enhanced fertilizers, NPKs etc. The
23 times huge revisions, the two most recent Senegal and South Africa. The table shows
Tunisia 0.5 1%
Morocco’s exports and about 3.5% of its t/a of sulphur each to feed sulphuric acid company estimates that in 2017 it sold 1.7
of which have come this century. The first that Africa is also responsible for 50% of GDP. Importantly, it also represents 30% of and phosphoric acid capacity. These have million tonnes of such speciality fertilizers.
Rest of world 1.5 2%
was in 2003, when Chinese phosphate traded phosphate rock on international the international market for rock phosphate roughly doubled MAP/DAP capacity at the One of the ways in which OCP is seeking
24 Total 67.0 100%
reserves were first massively revised markets, with North Africa accounting for and 40% of that for phosphoric acid. site to just under 8.0 million t/a. OCP has to differentiate itself is through offering sul-

25 upwards to nearly 7 billion tonnes as the 89% of that total, and Morocco alone 56%. Source: IFDC, USGS Most phosphate mining happens in the also built two massive drying plants at the phur-enhanced fertilizers. In 2016 it signed SULPHUR

ISSUE 375
Chinese government began releasing more However, Africa represents only 15% of north of the country, at Khouribga and Gan- site to dry the slurry concentrate as it arrives a deal with Shell to license the latter’s
reliable figures, and then downwards again tour, where most of the country’s proved from Khouribga so that it can maintain its Thiogro technology, which was installed at
26 to 3.7 billion tonnes once these reserves reserves lie. There is also a smaller mine exports of phosphate rock from Jorf at 10 production lines in Jorf Lasfar during 2017.
Table 2: African phosphate production, 2016 (million tonnes)
were judged to be overestimated. But more at Boucraa in Western Sahara. These in million t/a at the same time that it increases This allows OCP to incorporate micron-sized MARCH-APRIL 2018
27 eye catching still was the quadrupling of Phosphate rock (tonnes product) Phosphoric acid (tonnes P2O5) turn feed export facilities at Jorf Lasfar (for finished phosphate production there. particles of elemental sulphur into its exist-
estimated global phosphate reserves that Production Exports Production Khouribga), Safi (for Gantour) and Laay- Other new developments include ing ammonium phosphate, NPKs and cur-
28 occurred in 2010 as a result of a study oune (for Boucraa). upgrading of the existing Maroc Phosphore rent sulphur-enhanced products.
Algeria 1.3 1.2 0
by the International Fertilizer Development In 2007, OCP began its expansion lines 3 and 4 at Jorf Lasfar (originally part
29 Center (IFDC). Together with work by the
Egypt 4.3 3.1 0.1
strategy, intended to run to 2025, during of a joint venture with Brazil’s Bunge but Sulphur management
US Geological Survey, this has now put Morocco 26.9 7.9 9.5 which time it would double its phosphate brought back into full OCP ownership a cou-
30 global phosphate rock reserves at 67 Tunisia 3.7 0 1.0 rock production and triple its finished fer- ple of years ago) by 10% each, as well as All of this expansion in phosphate process-
billion tonnes, 80% of which is in North Other Africa 4.5 1.8 2.1 tilizer production. The first two phases of the addition of a new 500,000 t/a phos- ing will necessitate a similar expansion in
31 Africa, with Morocco and Western Sahara
Africa Total 40.7 14.0 12.7
this expansion are now mostly complete, phoric acid plant due for commissioning sulphuric acid production and consumption,
accounting for the vast bulk of this total, at an investment cost of $8 billion, and in 2019, and the commissioning of a new and hence sulphur imports. OCP has put con- Southbank House, Black Prince Road
World Total 200.0 27.6 83.3
32 as shown in Table 1. North Africa is impor- the third phase, from 2018-2025, is now 450,000 t/a phosphoric acid line at Laay- siderable effort into making sure it is able London SE1 7SJ, England
tant now for the phosphate industry, and in Source: IFA under way, as well as expansions at the oune in 2021, all of which will take OCP’s to handle this side of the logistical equa- Tel: +44 (0)20 7793 2567
33 the case of Morocco, for the sulphur indus- mine areas, especially Khouribga, where phosphoric acid capacity to 8.4 million tion, and the most recent fruit of this has
Fax: +44 (0)20 7793 2577

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2 phosphates

3
■ CONTENTS
4
5
been a long term sulphur sales agreement Djibouti to produce NPKs at Dire Dawa, joint venture is expected to be the first What’s in issue 375
signed with the Abu Dhabi National Oil Com- 250km east of Addis Ababa, using locally step in a broader strategic cooperation
pany (ADNOC), which is itself facing an issue produced ammonia and potash. The first between both groups that could include
6 with steadily increasing sulphur output from phase of the Ethiopia project will involve Kribhco’s investment in a phosphoric acid

7
its sour gas expansions at Shah and else- an investment of $2.4 billion, according unit in Morocco. ■ COVER FEATURE 1
where. ADNOC now produces 6 million t/a to OCP, with a second $1.3 billion phase

8
of sulphur and is likely to increase that over projected to increase the capacity of the Western Sahara Middle East
the coming years. It has recently become the facility to 3.8 million t/a by 2025.
world’s largest exporter of sulphur. Under the OCP has also recently signed a deal One fly in the ointment for Morocco has Sulphur
9 agreement, ADNOC, will supply OCP with an with IBM to provide digital and IT services in been the ongoing sovereignty dispute over
annually increasing amount of sulphur out to sectors ranging from agriculture to industry Western Sahara, which has recently blown Conference,
10 2025. ADNOC exported more than 2 million across Africa. The new joint venture, TEAL up into several lawsuits by Polisario, which Abu Dhabi
tonnes of sulphur to Morocco in 2016. Technology Services, will initially support claims to be the legitimate government of
11 OCP to accelerate its digital transforma- Western Sahara, to try and impound phos-
Overseas ventures tion and enhance efficiencies in its busi- phate rock exported from Laayoune. This led
12 ness operations, before moving to “create to two ships being stopped, one in Panama ■ COVER FEATURE 2
Finally, OCP is also looking to develop innovative solutions and services to drive and the other in South Africa (an attempt
partnerships in the wider world, especially digital transformation in industry and other to detain a third shipment, in Uruguay, was
13 North Africa’s
across Africa. In November 2016 it signed sectors important to Africa’s economic rejected by the local court there). Ironically,
14 a deal with Ethiopia to build one of the growth,” according to the two companies. exports form Laayoune represent only a frac- phosphate industry
world’s largest fertilizer facilities, with an Outside Africa, OCP has signed a joint tion of OCP’s rock exports every year, but
initial capacity of 2.5 million t/a. The plant, venture agreement with India’s Kribhco to the attendant publicity has led newly merged
15 which is expected to start producing fer- develop a 1.2 million t/a greenfield NPK North American phosphate importer Nutrien
tilizer in mid-2022, will import phosphoric fertilizer plant in Krishnapatnam, Andhra to recently say that its goal is not to import ■ COVER FEATURE 3
16 acid from Morocco via a new terminal at Pradesh at a cost of $230 million. The rock sourced from Western Sahara.

17
18
Fig. 1: Major phosphate producing facilities in North Africa
Increase your profits SRU combustion
challenges

19
20
Alexandria
Port Said with intelligent solutions ■ COVER FEATURE 4
Cairo
Giza
Suez
Sulphuric acid
21 Your challenge may be to invest in a bulk handling solution that ensures
plant simulation
22 profitable and sustainable growth for your business. Our expertise is to
23 provide just that solution. Virtually any dry bulk material can be handled
through safe and smooth Siwertell systems, and thanks to totally-enclosed
24 EGYPT

Algiers Annaba Tunis conveyors, the operation is free from dust and spillage.
25 SULPHUR

ISSUE 375
Algiers Annaba Tunis TUNISIA
Oran Luxor
26 Rabat Fes
Oran
TUNISIA
Djebel-Onk Gafsa
Sfax
Abu Tartur Sabaiya
Casablanca Djebel-Onk Gafsa
Sfax
La Skhira MARCH-APRIL 2018
27 Rabat Fes
Khouribga
CasablancaJorf Lasfar La Skhira Aswan
Benguerir
28 Jorf Lasfar Khouribga
Safi Youssoufia
ALGERIA
Benguerir
Safi Youssoufia MOROCCO
29 ALGERIA
Road-mobile
MOROCCO Ship unloaders ship unloaders Ship loaders Conveying Bulk terminal Parts & Service
systems solutions
30 KEY
Mine
31 Boucraa Major port
Laayoune Processing site Southbank House, Black Prince Road
Boucraa
32Laayoune WESTERN SAHARA
Proposed processing site
Phosphate pipelines
London SE1 7SJ, England
NEW siwertell.com Tel: +44 (0)20 7793 2567
WESTERN SAHARA
33 Fax: +44 (0)20 7793 2577
Siwertell is part of Cargotec
22 www.sulphurmagazine.com Sulphur 375 | March - April 2018 Web: w ww.bcinsight.com
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2 phosphates phosphates

3
■ CONTENTS
4
5 Algeria long it has taken Algeria to reach this stage, Table 3: North African sulphur reach 34%). Mining is in the hands of sev- phosphate capacity on the Red Sea coast. Africa thus represented 6.1 million t/a or What’s in issue 375
it seems certain that this date will slip. imports, million t/a eral companies, but the two largest are This is being funded with foreign partners just under 20% of global sulphur imports
After Morocco, moving eastwards along the the state owned Phosphate Misr and the including Italian and Chinese companies, in 2016, up from 14% in 2012, and mainly
6 coast we next come to Algeria, which has Tunisia 2012 2021*
military-owned El Nasr Company. Phos- and is due to come on stream in 2019. due to the start-up of the new plants at Jorf

7
the world’s third largest reserves of phos-
Algeria 0.0 0.4
phate Misr operates the Abu Tartour mine There is also Phosphate Misr’s El Wadi Lasfar in Morocco. ■ COVER FEATURE 1
phates after Morocco and China, at 2.2 Tunisia’s reserves of phosphate rock are in the New Valley area, opened in 1979, project, which will have 520,000 t/a P2O5 The expansions that have been dis-
billion tonnes P2O5. Algeria’s reserves are much smaller than its neighbours to the Egypt 0.2 0.9 which has some of the most concentrated of phosphoric acid capacity, and which is cussed in this article could see that rise
8 mainly the westward extension of Tunisia’s west, but by contrast with Algeria it has put Morocco 5.0 7.0 deposits (26-31% P2O5), and where annual due to come on-stream in 2021. considerably over the coming years. Table Middle East
Gafsa basin, with several prominent depos- much more effort into developing them, and Tunisia 0.9 2.1 production is around 2.1 million t/a from 3 gives a deliberately over-optimistic Sulphur
9 its running along the border with Tunisia. in 2010 Tunisia was the world’s fifth largest low cost ($15-20/t f.o.b.), open cast The role of sulphur potential projection of this, involving North
The Government-owned Entreprise nationale producer of phosphate rock, after China, the
Total 2.1 10.4
operations. The other major mines are African sulphur imports increasing by over Conference,
10 du Fer et du Phosphate (Ferphos) manages USA, Morocco and Russia, producing 8.1 * potential maximum, at capacity
Source: BCInsight
in the Nile Valley, around Sabaiya, also Neither Algeria or Tunisia have any appre- 4 million t/a to nearly 10.5 million t/a in Abu Dhabi
Algeria’s production of iron ore, phosphate million tonnes of rock. Two state owned com- surface mines, now operated by El Nasr. ciable elemental sulphur production, and 2021. This figure depends upon all of the
11 rock, and other key minerals, with phosphate panies operate Tunisia’s phosphate sector; The National Co. for Mining & Quarries (El Egypt and Morocco each produce only above projects coming to fruition with no
mining conducted by its subsidiary Société phosphate mining company Compagnie des Wataneya) also has a mine at Aswan with a modest amount (typically less than delays, and an end to Tunisia’s labour
12 des Mines de Phosphates SpA (Somiphos). Phosphates de Gafsa (CPG) and its down- 3.8 million t/a since then. Tunisia has had a capacity to produce 600,000 t/a of rock 100,000 t/a). The large scale growth disputes, allowing idled capacity to come ■ COVER FEATURE 2
Somiphos’ key site is the Djebel-Onk com- stream customer and processed phosphate nine governments in that time, but not one which re-started production in 2016. of domestic phosphate industries thus back on-stream. Of course, it is unlikely
plex, where there are an estimated 2.8 producer Groupe Chimique Tunisien (GCT). seems to have been able to tackle the Mining expansion is planned for Abu requires large volumes of sulphur imports that all of these will be the case, and any
13 North Africa’s
billion tonnes of phosphate rock deposits CPG has about 8.4 million t/a of phosphate country’s deep economic issues, and a new Tartour, adding 3 million t/a of phosphate in order to feed sulphuric and phosphoric potential oversupply in the global phos-
14 at 25-28% P2O5. Two main mines send rock capacity at five mines around the Gafsa round of strikes and blockades began at the rock production capacity by 2022. Down- acid production. As a result, Morocco phate market would likely see the time- phosphate industry
phosphate rock to a 2 million t/a capacity area. The rock is taken by rail to the port of start of February 2018. While the govern- stream projects to fall out of the current has become the world’s largest sulphur scales slip for projects. Continued political
beneficiation plant and onwards for export Sfax where about 1 million t/a is exported, ment has tried to use the phosphate indus- push towards monetising phosphate pro- importer, and Tunisia still ranks among the wrangling in Tunisia and Algeria are also
15 at the port of Annaba. A small amount is as well as to downstream production sites try as a source of jobs, more than doubling duction include the major El Nasr Interme- top five in spite of the downturn in its phos- likely to lead to further delays. Neverthe-
consumed domestically, but almost all of at Gabes, La Skhira, Sfax and M’dhilla, all the workforce from 13,000 to 27,000 peo- diate Chemicals (a subsidiary of El Nasr phate industry. Egypt imports around 200- less, the figures for Morocco, the largest ■ COVER FEATURE 3
16 Somiphos’ production is exported. of them operated by GCT, including triple ple, this has made the country’s phosphate Co) Ain Sukhna project, which will include 400,000 t/a. Algeria does not currently importer, may well be close to the mark.
However, the government has ambi- superphosphate production at Sfax and exports less competitive at a time when new 450,000 t/a P2O5 of phosphoric acid pro- figure as a sulphur importer because it cur- North African phosphates look set to be an
17 tious plans to revitalise and expand Alge- M’dhilla, and phosphoric acid (including low cost production is coming on-stream in duction, with downstream diammonium rently exports only phosphate rock and not increasing source of demand for sulphur
SRU combustion
ria’s mining sector. The first fruits of this merchant grade acid) at Gabes and Skhira, Morocco and Saudi Arabia. phosphate and 470,000 t/a triple super- processed phosphates. As a region, North over the coming years. n challenges
18 came via a new mining law passed in as well as downstream diammonium phos- Tunisia has plans for CPG to upgrade
2014, which revised the tax, fee and roy- phate production at Gabes. A 360,000 t/a phosphate production as well as additional
19 alty framework for the sector, including the new phosphoric acid plant came on-stream downstream processing at M’dhilla via an
introduction of exemptions on value-added at Skhira in 2013, a joint venture with Indian 800,000 t/a triple superphosphate plant. ■ COVER FEATURE 4
20 tax and customs duty for equipment, mate- fertilizer manufacturers Coromandel Interna- The latter – M’dhilla II – is due to come on-
rials and services used for mining explora- tional Limited and Gujarat State Fertilisers stream this year. It includes 200,000 t/a
Sulphuric acid
21 tion and production. and Chemicals Ltd (GSFC), each with a 15% P2O5 of merchant grade phosphoric acid
In the phosphate sector, the aim is stake, and Tunisia’s GCT and CPG, with the production. Radial Flow Stainless Steel Converters plant simulation
22 to open new mines at the Bled el Hebda remaining 70% between them. The joint ven- Experience:
deposit in the north of the country, where ture company is known as Tunisian-Indian Egypt • Introduced in 1981
23 there are reckoned to be 800 million tonnes Fertilizers (TIFERT) and exports its entire out- • Originally developed and patented by Chemetics
of phosphate rock. In 2016, Indonesian put to India as part of the JV agreement. In Egypt produced 4.3 million tonnes of phos- • Industry standard best in class design
firm Indorama signed three deals worth a order to process the phosphates, Tunisia’s phate rock in 2016, making it the seventh • More than 50 designed, fabricated and supplied by Chemetics
24
total of $4.5bn with state-owned Asmidal sulphuric acid capacity is 1,100 t/d at Sfax, largest producer in the world after China,
Features and Benefits:
25 and Manal to develop the mine along with 1,500 t/d at M’dhilla, 8,400 t/d at Gabes the USA, Morocco, Russia, Jordan and
• Radial flow design SULPHUR

ISSUE 375
downstream processing facilities. The new and 3,500 t/d at Skhira, for a grand total of Brazil, although the country was only just – Uniform gas distribution results in optimal catalyst performance
mine, a joint venture between Indorama and 14,500 t/d of acid or 4.8 million t/a, requir- ahead of rapidly increasing production in
26 Manal, would ultimately produce 6 million ing 1.6 million t/a of sulphur at capacity. Saudi Arabia. Egypt has the capacity to pro-
• All welded, contoured separation and support elements
– Eliminates gas bypassing
t/a of rock at capacity, multiplying Algeria’s While Tunisia has the second largest duce more than this and some years has – Low mechanical stress design uses up to 30% less stainless steel
MARCH-APRIL 2018
27 phosphate production fivefold. The associ- processed phosphates capacity and sul- produced over 6 million t/a. The country • No ‘Posts and Grates’ for ease of access and catalyst installation
ated fertilizer facility would include 3,000 phur requirement in North Africa, it has been has some of the lowest production costs • Round gas nozzles eliminates leaks, over 1000 years of leak free operation
28 t/d of diammonium phosphate production plagued since 2010 by unrest and strikes for its phosphate rock, and the government • Modular construction options to reduce cost and schedule risk
(Algeria already exports ammonia and so which have hit phosphate production hard. has decided to expand production and, • Flexible configurations, such as internal heat exchangers, for easy retrofits
29 would have plenty to spare for domestic Tunis was the cradle of the ‘Arab Spring’ like Morocco, capture more of it via down-
Innovative solutions for your Sulphuric Acid Plant needs
DAP production), 1,500 t/d of phosphoric which saw the ousting of its president Zine stream processing of phosphate rock.
30 acid production, and 4,500 t/d of sulphuric El Abidine Ben Ali in 2011. Unemployment Egypt’s phosphate deposits occur in a Chemetics Inc.
(headquarters)
Chemetics Inc.
(fabrication facility)
acid production in the first phase, with the and wages were a major cause of the dis- wide belt across the centre of the country, Vancouver, British Columbia, Canada Pickering, Ontario, Canada
31 potential for two similar complexes to fol- content, and the phosphate industry – the stretching from the Red Sea inland through Tel: +1.604.734.1200 Fax: +1.604.734.0340
email: chemetics.info@jacobs.com
Tel: +1.905.619.5200 Fax: +1.905.619.5345
email: chemetics.equipment@jacobs.com
low later if the phosphate mine expands to country’s major foreign currency earner – the Nile Valley and into the New Valley in Southbank House, Black Prince Road
32 full capacity. became a target for protestors. Tunisia’s the Western Desert. Egyptian phosphate www.jacobs.com/chemetics Chemetics Inc., a Jacobs company London SE1 7SJ, England
The initial target date for the complex to phosphate output fell to 2.5 million tonnes is however generally lower grade (20-30% Tel: +44 (0)20 7793 2567
33 be up and running was 2019, but given how in 2011, and has never recovered beyond P2O5 is typical, although some deposits
Fax: +44 (0)20 7793 2577

22 www.sulphurmagazine.com Sulphur 375 | March - April 2018 Sulphur 375 | March - April 2018 www.sulphurmagazine.com 27 Web: w ww.bcinsight.com
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2 CONFERENCE PREVIEW CONFERENCE PREVIEW

3
■ CONTENTS
4
5
Ben Franklin bridge and Philadelphia skyline. ‘Making America great again’: their marine fuels mix from 2018 through 2020 rollout and beyond What’s in issue 375
in compliance with the Rule and market pressures from shipown-
implications for the US and global economies ers. Meanwhile, refiners will feel the impacts of the IMO 2020 Rule
6

Sulphur
John M. Urbanchuk, managing director, differently based on class. Refineries currently producing HSFO will
Agriculture and Biofuels Consulting, LLP
7
be the most threatened by the Rule while those currently producing ■ COVER FEATURE 1
Austin Chamberlin, English statesman, scholar and brother of minimal HSFO will likely see IMO 2020 as an opportunity rather
Prime Minister Neville Chamberlin is credited with introducing than a threat. In any case, all players in the supply chain will have
8 Middle East

PHOTO: ULTIMA_GAINA/ISTOCKPHOTO.COM
the phrase: “may you live in interesting times” in the 1930s, to reckon with the effects of IMO 2020 sooner or later.

World Symposium Sulphur

and it is difficult to imagine a more appropriate economic and In his presentation, Ralph Grimmer will discuss compliance,
9 political environment than today where it applies. The presenta- enforcement, shipowner decision-making, market price and refin-
tion reviews the economic revitalisation that appears to have ery implications, changes in the marine fuels mix, capital invest- Conference,
10 accompanied the political revolution that ushered Donald Trump ments encouraged by the Rule, how IMO 2020 might be rolled out, Abu Dhabi

2018
into the presidency, prompted by an unprecedented rollback of and the potential impact on global sulphur production.
11 The Sulphur Institute’s annual World
regulations, tax cuts intended to restore competitiveness and
put money back into consumer’s pockets, accelerated growth
12 Sulphur Symposium comes to the Loews in output and improved employment environment. The outlook Caprolactam market review ■ COVER FEATURE 2
for the US economy is more positive now than at any time in
Philadelphia Hotel in Philadelphia, PA, recent years. Most of the other major world economies also Mark Victory, ICIS
13 North Africa’s
from April 23rd – 25th 2018. are experiencing a wave of growth and the IMF is predicting The abstract of this paper was not available at the time of going
MAIN SESSION PRESENTATIONS world growth of 3.9% this year up from 3.2% two years ago. to press. phosphate industry
14 However, significant challenges and threats remain. Accelerated

F
15
ollowing its move across the Atlantic to Dublin last year, The China’s “One belt, one road” initiative transforms real growth is likely to increase demand for commodities and
Sulphur Institute’s (TSI’s) annual World Sulphur Symposium is
global supply chains other materials and tight labour markets will push up labour Global sulphur and sulphuric acid market outlook
returning to the US in April. The Symposium is an annual con- costs. The result of this is likely to be a resurgence of inflation, ■ COVER FEATURE 3
16 ference that attracts international sulphur industry leaders from over David r. Meyer, Olin Business School, which has been dormant for the better part of the last decade. Claira Lloyd, David Tonyan, Argus Media
25 countries for two days of specialised speakers and networking Washington University in St. louis Concerns about overheating and inflation are expected to lead Claira Lloyd and David Tonyan from Argus will conduct a joint
17 events. Over 125 principal sulphur delegates are expected this year. China’s “One belt, one road” (Belt & Road) initiative is trans- to higher interest rates. On the political front threats range from presentation, with Claira covering the sulphur market and
SRU combustion
As well as the speaker presentations, an exhibition will be held forming global supply chains, especially across Asia, the Middle the possibility that the president may be indicted for obstruction David discussing sulphuric acid. Claira will assess this year’s challenges
18 as usual, this year held in the Regency Foyer outside Regency B, East, and Europe, and also extending to Africa. The supply chain of justice, continued unrest in the Middle East, war with North market, paying close attention to global near-term supply and
the TSI speaker session room. Coffee breaks will also be held in linkages are embodied in the Silk Road Economic Belt and New Korea, the implications of Brexit for Europe, and threats from demand drivers following sulphur’s unexpected year in 2017,
19 the Regency Foyer. Maritime Silk Road. One key part of the initiative aims to propel potential trade wars. when the market saw Middle East f.o.b. spot prices hit five
economic development within Asia, a process never significantly year highs and new buying parties enter the Chinese market. ■ COVER FEATURE 4
20 supported by the countries of Asia or by external actors, especially David will analyse the supply and demand factors driving the

Symposium Schedule
in Europe and North America. The Asian Infrastructure Investment IMO 2020: a sea change is coming sulphuric acid market in 2018, amidst a tight global market
Sulphuric acid
21 Bank (AIIB), which is organised like a typical multilateral develop- early in 2018. He will touch on relevant projects on both sides
ment bank, is headed by an elite group of experienced financial Ralph Grimmer, Stillwater Associates of the balance, and look ahead to new trade flows developing plant simulation
23 April 2012
22 and development executives. The bank is the financing vehicle for The International Maritime Organisation (IMO) is moving forward throughout the world. Key factors this year include consump-
09:00 - 11:00 TSI Annual General Meeting, Howe Room achieving intergovernmental cooperation. It serves as enabler of with its “IMO 2020 Rule” which will reduce the maximum sulphur tion levels in Chile and North Africa, and where traders will
23 (33rd floor). TSI Members only. the development process and expansion of infrastructure. This content of marine fuel (aka bunker fuel oil) to 0.5 wt.% in areas place Asian volumes. Strikes and copper prices are impacting
18:00 - 20:00 Welcome Reception, Howe Room and Atrium seed money supplements even larger sums from governments outside of Emission Control Areas (ECAs) unless onboard stack both supply and demand in Chile, while OCP in North Africa
(33rd floor). Co-sponsored by Shell Sulphur and private sector actors who will supply most of the capital. AIIB, gas scrubbers have been installed. This mandate was passed in continues to expand its phosphate capacity. European supply
24
Solutions and The Sulphur Institute. however, participates in only a small share of the projects; fund- 2008 as part of the MARPOL Annex VI rule, and will take effect on should see stability with no significant maintenances on the

25 ing sources are diverse. Key infrastructure components include January 1st 2020. Implementation of IMO 2020 will have a pro- docket for 2018.The North American market has several new SULPHUR

ISSUE 375
24 April 2012 railroads, highways, telecommunications (fibreoptic lines), ports, nounced impact on relative market prices for marine fuels, other consuming projects either ramping up or scheduled to come on
08:30 - 09:00 Coffee and Continental Breakfast power plants, and dams. This infrastructure is being integrated by refined products, and crude oil on a global basis. Beginning on line and new terminals already scheduled or being considered
26 Sponsored by Oxbow Sulphur Inc. sea and by land. It opens a large territory within Asia (e.g., Sibe- January 1st 2020, marine fuel options will include compliant 0.5 on the west coast.
09:00 - 10:30 Speaker Session 1 ria, Kazakhstan, Mongolia), previously inaccessible or with poor wt.% sulphur marine fuel, high sulphur fuel oil (HSFO) in tandem MARCH-APRIL 2018
27 10:30 - 11:00 Coffee Break infrastructure, to resource development. Successful implementa- with a scrubber or in violation of the rule, or an alternative fuel

28
11:00 - 12:30 Speaker Session 2 tion of this initiative will accelerate Eurasian, Middle East, and such as liquefied natural gas (LNG). The outlook for phosphate markets: what’s next?
12:30 - 13:30 Lunch African development and lead to greater economic integration and The impact of the rule and its market pricing will be keenly felt
Sponsored by Savage Services Corporation. restructuring of global supply chains. Numerous projects in Asia, by all participants in the marine fuel chain – ship owners, marine Andy Jung, The Mosaic Company
29 18:00 - 19:30 Evening Reception Europe, the Middle East, and Africa are already underway. China’s fuel suppliers, refiners, and associated industry sectors. Ship own- The global phosphate market remains in a period of transition.
strategy is to draw on the global financial expertise in London and ers must take into account many factors when determining how to Last year was characterised by new capacity ramping up in the
30 25 April 2012 Hong Kong to identify and organize the vast amounts of capital comply with IMO 2020. Some of these factors include the cost of Middle East and North Africa, offset later in the year by a slow-
08:30 - 09:00 Coffee and Continental Breakfast that will be needed for “Belt & Road” projects. These capital flows installation and operation of new equipment on their vessel(s), the down in Chinese exports and the idling of Mosaic’s Plant City facil-
31 09:00 - 10:30 Speaker Session 3 will contribute to the internationalization of the renminbi. Global age of the vessel, trading routes, market economics, availability of ity. This presentation provides an overview of the aforementioned
10:30 - 11:00 Coffee Break companies need to plan their approaches to participate in the equipment, and the viability of exhaust gas scrubbers. Industry cap- transitional changes, including how they’re expected to influence Southbank House, Black Prince Road
32 11:00 - 12:30 Speaker Session 4 “Belt & Road” initiative and to develop supply chain strategies ital investments – scrubbers on board vessels and refinery resid the market in 2018, as well as detailing other key factors to watch London SE1 7SJ, England
12:30 - 13:30 Lunch that leverage this dramatic restructuring of interconnectivity across upgrading – will be required and will look attractive if price differen- that could have an outsized impact on the global phosphate sup- Tel: +44 (0)20 7793 2567
33 Eurasia, the Middle East, and Africa. tials widen durably. Fuel suppliers, for their part, will have to adjust ply/demand balance in 2018 and beyond. n
Fax: +44 (0)20 7793 2577

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2 PROCESS PLANT SURVEY PROCESS PLANT SURVEY

3
■ CONTENTS
4

Sulphur recovery
5 Operating Operating Process Total new Licensor(s) Lead Project Planned What’s in issue 375
company site type capacity contractor type start-up date
6
INDIA

plant listing 2018

7 Essar Oil Vadinar Claus, SCOT 675 t/d Jacobs n.a. New 2019
■ COVER FEATURE 1
Reliance Jamnagar O2, NH3, amine TGT 4 x 1,300 t/d WorleyParsons n.a. New 2018
8 HPCL Vishakhapatnam Claus 2 x 360 t/d n.a. n.a. New 2020 Middle East
IOCL Panipat Claus, TGT 225 t/d PROSERNAT n.a. New 2020
Sulphur
9 IOCL Mathura Claus, TGT 2 x 425 t/d PROSERNAT n.a. New 2020
Sulphur’s annual survey of recent current and future sulphur recovery unit IOCL Bongaigon Claus, TGT 20 t/d PROSERNAT n.a. New 2020 Conference,
10 construction projects maps the developing shape of brimstone production
IOCL Bathinda Claus, TGT 750 t/d PROSERNAT n.a. New 2019
Abu Dhabi
INDONESIA
11 from fuel and gas processing plants worldwide. PT Medco E&P East Aceh EuroClaus 48 t/d Jacobs n.a. New 2019
PT Pertamina Cepu Claus, SCOT 122 t/d Jacobs n.a. New 2018
12 Pertamina Balongan Claus, NH3, H2, amine TGT 1,100 t/d Amec Foster Wheeler n.a. New n.a. ■ COVER FEATURE 2
IRAQ
Operating Operating Process Total new Licensor(s) Lead Project Planned
13 company site type capacity contractor type start-up date Turkish Pet Int Mansuriyah Claus, amine 230 t/d WorleyParsons n.a New 2019
North Africa’s
ISRAEL
14 Bazan Haifa Refinery O2 enrich 3 x 100 t/d WorleyParsons n.a. Revamp 2018 phosphate industry
ALGERIA
Sonatrach Tiaret, Hassi Messaoud Claus, TGT, amine, SWS 14 t/d n.a. Amec Foster Wheeler New 2020 KAZAKHSTAN
15 ARGENTINA
Pavlodar Oil Chem Pavlodar Refinery Claus, TGT 180 + 260 t/d Siirtec Nigi Rominserv, Technip New 2018

AXION Energy Campana Claus, TGT 2 x 30 t/d PROSERNAT PROSERNAT New 2018 KUWAIT ■ COVER FEATURE 3
16 Chevron Wafra Claus, amine 2 x 218 t/d WorleyParsons n.a. New 2018
AZERBAIJAN
KNPC Al Zour Refinery Claus 1,500 t/d Amec Foster Wheeler n.a. New 2019
17 SOCAR Baku HAOR Claus, TGT amine 2 x 30 t/d Tecnimont, UOP Amec Foster Wheeler New 2021
KOC JPF Claus, TGT 2 x 100 t/d Siirtec Nigi Schlumberger New 2018 SRU combustion
H2S, CO2 Amec Foster Wheeler
KOC JPF SmartSulf 2 x 100 t/d PROSERNAT PROSERNAT New 2018 challenges
18 BAHRAIN KNPC Mina al Ahmadi Claus, amine TGT 2 x 400 t/d WorleyParsons n.a. New 2019
Bapco Sitra Refinery Claus, NH3, amine 3 x 250 t/d WorleyParsons n.a. New 2020
MALAYSIA
19 SWS, AGRU
Petronas Johor SuperClaus 3 x 470 t/d Jacobs n.a. New 2019
BELGIUM
MEXICO
■ COVER FEATURE 4
20 ExxonMobil Antwerp Refinery O2 enrich, amine, TGT 325 t/d WorleyParsons Amec Foster Wheeler Revamp 2018
PEMEX Duba SRU n.a. n.a. Amec Foster Wheeler New 2018
n.a. Antwerp Claus, TGT 490 t/d n.a. Amec Foster Wheeler Revamp 2018
PEMEX Cadereyta SmartSulf, NH3 132 t/d WorleyParsons n.a. New On hold Sulphuric acid
21 BRAZIL
Petrobras Premium I SuperClaus 2 x 240 t/d Jacobs n.a. New Cancelled
PEMEX Tula, Hidalgo EuroClaus 3 x 640 t/d Jacobs n.a. New 2019
plant simulation
NETHERLANDS
22 Petrobras Premium II SuperClaus 240 t/d Jacobs n.a. New Cancelled
Total/Lukoil Zeeland SWS n.a. Amec Foster Wheeler Amec Foster Wheeler Revamp 2020
Petrobras Rio de Janeiro SuperClaus 2 x 62 t/d Jacobs n.a. Revamp 2018
23 CAMEROON
NIGERIA
Dangote Oil Lekki Refinery SuperClaus 2 x 115 t/d Jacobs n.a. New 2019
SoNaRa Limbe SRU, SWS 17 t/d Amec Foster Wheeler KT Kinetics Tech New 2018
24 OMAN
CHILE
OOC Duqm Refinery Claus, H2, SWS, amine 3 x 355 t/d Jacobs Tecnicas Reunidas New 2021
25 ENAP Aconcagua EuroClaus 45 t/d Jacobs n.a. Revamp 2018 SULPHUR

ISSUE 375
ENAP Biobio PERU
Repsol La Pampilla 2 x Claus, NH3, O2, 37 t/d Amec Foster Wheeler n.a. New n.a.
26 CHINA
H2, amine, TGT
Jiutai Energy Linyi, Shangdong EuroClaus 32 t/d Jacobs n.a. New 2018
POLAND MARCH-APRIL 2018
27 Sinopec Fujian SuperClaus 513 t/d Jacobs n.a. New 2018
Grupa Lotos Gdansk Refinery O2 enrich 2 x 60 t/d WorleyParson Tecnimont Revamp 2018
Shaanxi Yancheng Yulin, Shaanxi EuroClaus 41 t/d Jacobs n.a. New 2018
QATAR
28 COLOMBIA
EcoPetrol Barrancabermeja Claus, NH3, amine 2 x 130 t/d WorleyParsons n.a. New On hold Qatar Petroleum Mesaieed Sour gas, AGE, 310 t/d Worley Parsons Petrofac/Black&Veatch Revamp 2018
Claus, TGT Prosernat
29 CROATIA
INA Rijeka Claus 95 t/d WorleyParsons n.a. New 2019 RUSSIA
30 EGYPT
Bashneft Ufa Amine, SWS n.a. Amec Foster Wheeler n.a. New 2023
Bashneft Ufa SmartSulf 115 t/d PROSERNAT n.a. New 2018
MIDOR Alexandria Claus 410 t/d n.a. n.a. New 2018
31 FRANCE
Gazpromneft Moscow LPG treat, amine n.a. Amec Foster Wheeler Amec Foster Wheeler New 2019
Lukoil Volgograd NH3, H2, amine 2 x 76 t/d Fluor n.a. New 2018
Total Donges SWS n.a. Amec Foster Wheeler Amec Foster Wheeler New 2021 Southbank House, Black Prince Road
32 Total Normandy SuperClaus 96 t/d Jacobs n.a. Revamp 2019 Mariisky Mari El Republic
TGT, D’GAASS
SRU, TGT, amine n.a. Shell Amec Foster Wheeler New Suspended
London SE1 7SJ, England
Tel: +44 (0)20 7793 2567
33 Fax: +44 (0)20 7793 2577

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4
5 Operating Operating Process Total new Licensor(s) Lead Project Planned What’s in issue 375
company site type capacity contractor type start-up date
6
RUSSIA continued
7 Rosneft Saratov EuroClaus 283 t/d Jacobs UOP New 2020
■ COVER FEATURE 1
Orsknefteorg Orsk EuroClaus 2 x 99 t/d Jacobs n.a. New 2018
8 Taneco Nizhnekamsk Claus, TGT 3 x 410 t/d WorleyParsons n.a. Revamp 2019 Middle East
SAUDI ARABIA Sulphur
9 PetroRabigh Rabigh EuroClaus 292 t/d Jacobs n.a. New 2019
Saudi Aramco Tanajib Gas Plant Claus, O2 enrich, amine 3 x 1,000 t/d WorleyParsons n.a. New 2020 Conference,
10 SERBIA Abu Dhabi
NIS Pancevo Refinery Claus, NH3, amine 170 t/d WorleyParsons n.a. Revamp 2019
11 SINGAPORE
SRC Jurong Island Claus, O2 enrich, NH3 145 t/d WorleyParsons n.a. Revamp On Hold
12 SRC Jurong Island SuperClaus 2 x 65 t/d Jacobs n.a. Revamp 2019
■ COVER FEATURE 2
ExxonMobil Pulau Ayer SuperClaus 400 t/d Jacobs n.a. New 2020
13 SOUTH AFRICA North Africa’s
14
Chevron Cape Town Claus, SCOT 2 x 45 t/d Jacobs Fluor Revamp 2019-20 phosphate industry
SOUTH KOREA
15 Hyundai Daesan O2 enrich 410 t/d WorleyParsons n.a. Revamp 2018
S-Oil Onson Claus, amine, TGT, SWS 2 x 220 t/d Amec Foster Wheeler Amec Foster Wheeler New 2018
C
■ COVER FEATURE 3
16 SPAIN
M
Cepsa Algeciras Claus, SCOT 280 t/d Jacobs n.a. New 2019
17 BP Oil Castellon EuroClaus 2 x 45 t/d Jacobs n.a. Revamp 2018 J
SRU combustion
THAILAND CM
challenges
18 Thai Oil Sriracha Refinery Claus, NH3, Flexsorb 2 x 837 t/d WorleyParsons Amec Foster Wheeler New 2021 MJ

TURKEY
19
CJ

STRAS Aliaga/Izmir SRU, TGT, amine, SWS 463 t/d Tecnimont KTI Amec Foster Wheeler New 2018
Tupras Izmir Degassing 73 t/d Jacobs n.a. New 2018
CMJ
■ COVER FEATURE 4
20 Tupras Izmir EuroClaus 240 t/d Jacobs n.a. New 2020 N

Tupras Kirikale EuroClaus 135 t/d Jacobs n.a. New 2020 Sulphuric acid
21 TURKMENISTAN
Turkmenbashi Oil Turkmenbashi City SuperClaus 25 t/d Jacobs Hyundai New n.a.
plant simulation
22 UNITED ARAB EMIRATES
IPIC Fujairah SRU, SWS, amine TGT 330 t/d Amec Foster Wheeler n.a. New 2018
23 Al Hosn Gas Shah n.a. 4 x 1250 t/d n.a. Amec Foster Wheeler New 2022

24 UNITED STATES
Chevron Richmond, CA O2 enrich 580 t/d WorleyParsons n.a. Revamp 2018
25 UNITED KINGDOM SULPHUR

26
Eni
UZBEKISTAN
Point of Ayr Claus, amine, TGT n.a. WorleyParsons n.a. Revamp 2018
ISSUE 375
Lukoil Kandym SuperClaus, TGT 2 x 405 t/d Jacobs n.a. New 2018 MARCH-APRIL 2018
27 Mubarek Mubarek Gas Plant Claus, amine 1,000 t/d WorleyParsons n.a. New 2020
VENEZUELA
28 PDVSA El Palito SRU, amine, TGT, SWS 250 t/d Shell Amec Foster Wheeler New 2018
PDVSA Puerto La Cruz Claus, NH3, amine 2 x 225 t/d WorleyParsons n.a. New 2019
29 VIETNAM
Bin Son Refinery Dung Quat Claus, SCOT, TGT, SWS 2 x 105 t/d Jacobs, Amec Foster Wheeler New 2019
30 Amec Foster Wheeler
Key
31 AGE: Acid gas enrichment O2: Oxygen enrichment SRU: Sulphur recovery unit To learn more
AGRU: Acid gas removal unit NH3: Ammonia destruction SWS: Sour water strip Southbank House, Black Prince Road
32 BTX: BTX destruction H2: Hydrogenation TGT: Tail gas treatment unit London SE1 7SJ, England
Fuel: Fuel gas supplemental burning SCOT: Shell Claus offgas treating n.a: Information not available Tel: +44 (0)20 7793 2567
33 axens.net/blog Fax: +44 (0)20 7793 2577

33 www.sulphurmagazine.com Sulphur 375 | March - April 2018 ISO 9001 – ISO 14001 – OHSAS 18001 – ISO 50001 Web: w ww.bcinsight.com
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1

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2 Sulphuric acid plant SimulatorS Sulphuric acid plant SimulatorS

3
■ CONTENTS
4
5
6
The digital world Fig. 3: Freezing point of sulphuric acid solutions1

800
What’s in issue 375

of sulphuric acid
7 600
boiling point of sulphuric acid solutions at one atmosphere
■ COVER FEATURE 1

8
400
Middle East
200
Sulphur
9

temperature, °F
50
Simulator engines have come a long way from their humble beginnings. in this article freezing point of sulphuric acid solutions Conference,
25
10 Chemetics, Haldor Topsoe, NOrAM and Outotec report on some of the latest developments and Abu Dhabi
0
11 applications of simulation and modelling to improve the profitability, design and operation of liquid
-25
sulphuric acid plants.
12 solid
■ COVER FEATURE 2

pHOTO: CHEMETICS
-50

-75
13 North Africa’s
P
rocess simulator programs have to troubleshoot and debottleneck exist- 0 10 20 30 40 50 60 70 80 90 100

14 been widely adopted in chemical ing plants. By developing accurate models sulphuric acid, % by weight phosphate industry
plant designs during the last two that simulate the effects of changes to Fig. 2: New Chemetics SARAMET® acid towers with modelling process
decades and the sulphuric acid industry the plant conditions, deviations and mal- design confirmed using plant operational data.
15 is no different. Plant modelling using pro- functions can be simulated in the “virtual
cess simulators is an indispensable tool plant” to allow operators to quickly deter- the critical issues that is often overlooked for pure components, and selected common ■ COVER FEATURE 3
16 for process engineers, plant engineers and mine the root cause of the problem before even by experienced plant engineers or mixtures that exhibit close to ideal behaviour.
Fig. 4: Changes in specific density of
sulphuric acid/oleum relative
designers. the issue becomes catastrophic, forcing process designers is that when they see Modern simulators have a large number of
17 The classic application of simulators the plant to be shut down for repairs. a result generated by the simulator, they property estimation methods available for
to acid concentration2 SRU combustion
is for calculation of the mass and energy Process simulators allow actual plant assume it must be correct. Without first the user and some software packages even challenges
18 balance, which forms the basis of process operating data to be fed into the created validating the model and its inputs, the allow the end user to create their own prop- 2.00
flow diagram (PFD) development. The PFD plant model and allow the end user to output of the model can suffer from the erty estimation equations to improve the 1.95

specific density
19 is one of the key engineering documents quickly predict the expected performance classic “garbage in, garbage out” problem. accuracy of the property predictions. 1.90
that forms the basis for sizing the plant of the plant. However, in many cases plant Fundamentally the results are based on It is critical for the process model 1.85 ■ COVER FEATURE 4
20
PHOTO: CHeMeTiCS

equipment, piping, and ducting. This type data that is collected is typically incomplete the simulator engine executing the inputted designer to select appropriate property 1.80
1.75
of application is typically known as static and at times inconsistent due to changes calculations. The simulator engine will exe- models for the chemical process to be
1.70 Sulphuric acid
21 simulations as the problem is solved for a in operating conditions during data collec- cute whatever it is told to, exactly as it is told simulated. In most cases no single prop- 80 85 90 95 100 105 110
particular steady state. tion; the equipment may not be performing to even if that makes no sense in the real erty estimation method can predict proper- sulphuric acid concentration, %
plant simulation
22 Another application for process simula- as originally designed due to wear, foul- world system that is being modelled. Exam- ties for all the chemical components in a
tors is looking at the real time response Fig. 1: Modern sulphuric acid plant with ing or even premature failure, and there ples where this can occur are errors in the plant. Before selecting a property method
23 of the plant when an input or parameter process design optimised using modelling. are many constraints that can’t be input connectivity between process units, incor- calculation, the designer should check to
is changed. The model essentially runs directly into the model. Some of the extra rect shortcut calculations to improve con- ensure the method selected is appropriate of the acid changes the liquid changes from
in real time and mimics the behaviour of important to validate all the assumptions, constraints are physical restrictions at the vergence and calculation time, errors during for the mixture of the components, tem- a fully hydrolysed (aqueous) state to vari-
24
the actual plant. This type of application is inputs/outputs, and property estimation site, cost differences depending on exist- data entry, invalid reactions, and using the perature and pressure of the process, and ous hydrates such as tetrahydrate (H2SO4-

25 known as dynamic simulation. methods by specialists experienced in the ing equipment and its condition, and time wrong calculation methods or physical prop- the availability of parameters for the calcu- 4H2O), hemihexahydrate (H2SO4-6½ H2O) SULPHUR

ISSUE 375
There are many types of process process in question. to implement changes. To address these erty models. Although most modern simula- lations in these ranges. and octahydrate (H2SO4-8H2O).
simulators but they are all essentially a One of the major benefits of process challenges, some process simulators can tors have built-in error checking routines to For the case of simulating sulphuric acid
26 mathematic solver (simulator engine) that simulators is that designers can look now connect to the plant control systems warn the user with obvious input errors, it plants it is particularly challenging because Chemetics simulation and modelling
requires the user to provide physical prop- at the sensitivity of changes of various such as DCS, PLCs, etc. directly and col- is still up to the engineer to ensure all the in the typical operating range of sulphuric MARCH-APRIL 2018
27 erties of the materials components (e.g. parameters once the basic plant model is lect plant data in real time. This improves assumptions and parameters used in the acid plants (80-100 wt-% H2SO4), the fluid Chemetics started to develop “in-house”
sulphur, sulphuric acid, air, water, etc.), set up in the simulator. The designer can the quality of the data input into the model model are appropriate for the situation. is considered non-aqueous and does not process simulator programs using spread-
28 definition of chemical reactions (e.g. S + adjust parameters to optimise the plant but it is still up to the engineer to deter- When using a commercially available behave like ideal fluids, due to the various sheets and programming languages such
O2 → SO2), material and energy inputs/ process design to achieve the client’s mine if the data reflects the actual operat- process simulator, it is critically important to hydration states that exists. This makes as Fortran and Basic back in the 1980s.
29 output, equipment models and economic objectives. This enables engineers to com- ing conditions of the plant. validate that the property estimation meth- modelling physical properties using tradi- Currently Chemetics uses both in-house
information. This completed process plete sophisticated design, development, ods used in the model are appropriate for tional methods such as equation of state, proprietary plant simulators as well as com-
30 model is then solved by the simulator analysis, and optimisation of plant designs Limitations of process simulators the chemical process in question. Significant activity coefficients, etc. difficult to reflect mercially available process simulators soft-
engine which calculates the mass and before significant resources are committed errors can result from either (a) incorrect the actual real world data. A great example ware to fulfill the needs of plant operators.
31 energy balance with temperatures, pres- for detailed engineering. This inherent ben- Despite the advances in process simulator physical property data that feeds to the prop- to illustrate this is the freezing point curve1
sures, compositions, costs, etc. for each efit to quickly simulate different operating technology, all process models created in erty estimation calculation, or (b) inappro- of sulphuric acid (see Fig. 3), there are mul- Customisation of physical properties Southbank House, Black Prince Road
32 stream solved as the output. parameters of a sulphuric acid plant allows the simulator are still only a representa- priate estimation methods to calculate the tiple sharp inflection points on the freezing Sulphuric acid and oleum have properties London SE1 7SJ, England
Before a process model can be used process engineers to not only design and tion of the plant in question, and they are physical properties that are used. Reliable point curve as the acid strength changes that are highly non-linear with concentra- Tel: +44 (0)20 7793 2567
33 to simulate an existing process, it is optimise new greenfield plants but also not the exact replica of the plant. One of physical property data typically only exists from 0 to 100 wt-% H2SO4. As the strength tion, as an example the density increases
Fax: +44 (0)20 7793 2577

33 www.sulphurmagazine.com Sulphur 375 | March - April 2018 Sulphur 375 | March - April 2018 www.sulphurmagazine.com 35 Web: w ww.bcinsight.com
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1

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2 Sulphuric acid plant SimulatorS

3 34th
■ CONTENTS
4 Oil | Gas | Fertilizers | Metallurgy | Industrial

Sulphur 2018
5 Table 1: Summary of scenarios What’s in issue 375
6 Key observation accounted for? Scenario
Bed 4 catalyst CHX leak CRHX leak HHX IRHX CHX + CRHX
7 Emissions yes yes yes no yes yes
■ COVER FEATURE 1
∆SO2 across CHX no yes no no no yes
8 Middle East
SO3 after CRHX no no yes no no yes
5-8 November 2018 Sulphur
Gothia Towers, Gothenburg, Sweden
SO3 after IRHX no no yes no yes yes
9
Likelihood (based on condition) low (mostly new) high high certain unknown (not inspected) high Conference,
10 Source: Chemetics Abu Dhabi
11
with increasing concentration, but essen- scenarios could account for the specific the existing twin gas exchangers reach the
12 tially levels off above ~93%, and then differences seen in the plant vs the base- end of their services lives, a study was per- ■ COVER FEATURE 2
actually decreases slightly by 100%. In the line flow sheet performance. formed to determine if a single new high
oleum range the density increases again, The results indicated a major leak on efficiency TGR Exchanger could replace
13 North Africa’s
2018 CALL FOR PAPERS
with a much steeper slope than in the acid the cold reheat gas exchanger and a minor both the existing TGR Exchangers while
We are delighted to invite all
14 range. This effect is summarised in Fig. 42. leak in the cold exchanger. The plant can addressing the need for a SO3 Cooler.
organisations to submit an abstract for
phosphate industry

DEADLINE
Changes in direction or discontinuities in use this to prepare repair and replace- Using process simulators with vali-
slope of the property values cause errors ment plans prior to the next turnaround dated data from plant operations, the consideration for the 2018
15 when using standard property packages. and avoid costly additional downtime. An plant model confirms that it is possible to programme.

30 APRIL 2018 ■ COVER FEATURE 3

Chemetics uses several different cus- additional benefit of developing this plant replace the existing low efficiency carbon
16 Subject areas include:
tomised property sets for sulphuric acid at model was that it becomes a tool for the steel exchangers with a single radial flow,
various concentration ranges to accurately operators to determine the optimal oper- high efficiency stainless steel TGR (Fig. 5). Desulphurization of fossil fuels
17 calculate physical property relationships. ating parameters to maintain acceptable This finding provides tremendous value SRU operations and
SRU combustion
Chemetics has done extensive customisa- emissions while the long term repair plans to the client as it eliminated the need for a For over 30 years, Sulphur has been the industry’s troubleshooting challenges
18 tion of physical properties specific to the are being prepared and executed. new SO3 cooler fan installation and asso- leading technical event where the global sulphur
Environmental compliance and
sulphuric acid industry to address these ciated equipment, thereby significantly community meets to learn about new technical and emissions management
19 issues3. Two examples where Chemetics Debottlenecking a metallurgical acid plant reducing capital and operating costs. In process developments, share operational experience
has used simulator models for troubleshoot- A metallurgical sulphuric acid plant uti- addition, this has the added benefit of sim-
and discuss best practice.
Sulphuric acid operations and ■ COVER FEATURE 4
20 ing and debottlenecking are given below4: lises parallel tail gas reheat exchangers plifying the control system used to regulate troubleshooting
Troubleshooting in a regen sulphuric
(TGR exchangers) made out of carbon acid plant temperatures. With the use of
By submitting an abstract you will have the
Sulphuric acid plant design, Sulphuric acid
21 steel to partially cool the SO3 gas enter- a low pressure drop, radial flow stainless
catalysts and equipment
acid plant ing the absorption tower and to reheat the steel tube design, it eliminated the need opportunity to contribute to peer-to-peer industry plant simulation
22 A regeneration sulphuric acid plant was tail gas (unabsorbed gas from the absorp- for future (and expensive) re-tubing of the Logistics, handling & forming
learning, demonstrate thought leadership, and
suffering from slowly worsening SO2 emis- tion tower) going to the plant stack. When existing carbon steel TGR exchangers.
showcase the latest technical and process
23 sions. Repairs had already been attempted
developments to improve production efficiency.
on the hot heat exchanger; however, the
emissions were still getting worse to the
24
point of forcing production rate reductions. For more information and details of the selection criteria please visit www.sulphurabstracts.com
25 The site was limited in access to some SULPHUR

ISSUE 375
sampling locations and to the accuracy of or contact Amanda Whicher. Amanda.whicher@crugroup.com +44 (0)20 7903 2884
the measured temperatures, concentrations
26 and flows due to the age of the instruments.
MARCH-APRIL 2018
OPERATORS PAY
The site data did not provide a clear cause For sponsorship and exhibition enquiries please contact
27

E 8
for the performance issues so a modelling

ON 01
Michelle Fisk
ONLY £550

IT 2
study was initiated to help determine the

M UR
28 michelle.fisk@crugroup.com

ADLPH
cause of the performance issue.
FOR AN ACCESS ALL AREAS

SU
To execute the modelling study mod- +44 (0)20 7903 2159
29 els were prepared with different plausible PASS
failures. Examples of these models are
30
pHOTOS: CHEMETICS

leaks in each gas exchanger or degraded Official Publications: Supporting publication:

catalyst in certain beds. The models were
31 adjusted to match the observed plant data
as closely as possible. Each model was Southbank House, Black Prince Road
32 then compared with the whole set of plant London SE1 7SJ, England
data, gas sampling results, and other Fig. 5: Chemetics radial flow tail gas reheater installed. Unit process design developed by creating a Tel: +44 (0)20 7793 2567
33 observations to determine which failure model of current plant operation and optimizing the unit to achieve desired plant performance.
Fax: +44 (0)20 7793 2577

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For more information and to book you place please visit www.sulphurconference.com www.bcinsightsearch.com
1

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2 Sulphuric acid plant SimulatorS Sulphuric acid plant SimulatorS

3
■ CONTENTS
4
5 Fig. 6: NORAM dynamic simulation of converter preheating. Left: Catalyst heat- l Inlet temperature to converter bed 4 Fig. 7: NORAM CFD simulation for gas mixing. Left: Existing design. Right: Upgraded Topsoe simulation of the sulphuric What’s in issue 375
up curves with 100% of the hot gas fed to bed 1. Right: Catalyst heat-up (uniform temperature is preferred). design. See numeric values on left side of each plot for temperature predictions
Inlet gas velocity to converter bed 4
acid converter
curves with heating of all four beds simultaneously. l
6 (uniform velocity is preferred). Capable software for acid plant simulation

7 Gas t from B-103 bed 1 cat t bed 2 cat t bed 3 cat t bed 4 cat t
l Process gas pressure drop (low pres- is a crucial tool to be able to fully under- ■ COVER FEATURE 1
sure drop is preferred). stand the behaviour of the plant at specific
l Inlet concentration profile of O2 and SO2 conditions, and to predict how well new
8
600
500
600
500 to converter bed (uniform concentra- concepts, such as new layouts or catalyst Middle East
Sulphur
temperature, °c
temperature, °c

400 tions are preferred). solutions will perform.

400
9 l Overall conversion of converter bed Over the past decades, the design of
300 300
(maximum conversion is preferred). converter catalyst loading in a sulphuric Conference,
200 200
10 100 100
acid plant has evolved from simple rules Abu Dhabi
Fig. 7 shows the CFD results. The perfor- of thumb, via simple computer simulations
0 0
11 0 2 4 6 8 10 12 14 16 18 0 2 4 6 8 10 12 14 16 18
mance of the existing design was com- and basic models, to the advanced models
time, hours time, hours pared against the new design: available today7 (see Fig. 8).
12 The capabilities of different parties to ■ COVER FEATURE 2
Source: NORAM Existing design predict the response of the converter will
The simulation results of the bed temperature differ, as will the need. A plant manager
13 North Africa’s
above converter bed 4 for the existing design or plant engineer will typically have some
14 NORAM Engineering simulator For the new design where all four beds are shown in Fig. 4 (left). It is clear that the rules of thumb they use to assess perfor- phosphate industry
are preheated simultaneously, all four beds gas mixing for this geometry is not complete. mance of the converter, while most cata-
models heat-up evenly, and reach 800+°F in approxi- For this reason, the temperature above lyst vendors and engineering companies
15 NORAM Engineering specialises in the mately ten hours. The required hot preheat bed 4 is not uniform and varies from 752 to will have computer models that offer more
design and debottlenecking of sulphur- gas flow distribution between converter 866°F (400 to 463°C). The deviation in gas detailed insight into how to the converter ■ COVER FEATURE 3
16 burning, acid regeneration and metallurgi- beds is as follows: 24.0% to bed 1; 30.4% temperature was 114°F (63°C). In this case will behave at different conditions. The
cal sulphuric acid plants and equipment to bed 2; 32.7% to bed 3; 12.9% to bed 4. the conversion of bed 4 would be affected more advanced the models that are avail-
17 and uses sulphuric acid plant simulation The simulation shows how the plant due to the variation in temperature. able, the better the predictions and the
SRU combustion
to investigate, diagnose and optimise the can be heated-up faster to the target tem- more detailed predictions can be made, challenges
18 sulphuric acid plant5 (see Sulphur No. 359, peratures. This also provides flexibility in New design especially at conditions that are further
pp. 43-45). Some examples of applica- case the client prefers to increase the The gas streamlines and the bed tem- from “standard”. The extra detail can be
19 tions where NORAM has used simulator heat-up rate of a certain bed. Tight shut-off perature above bed 4 are shown in Fig. 7 utilised to optimise the plant further or
models are given below6. valves and spectacle blinds are provided to (right). In this case, the temperature above Source: NORAM even to evaluate new plant configurations. ■ COVER FEATURE 4
20 get back to the original design conditions bed 4 is much more uniform. The tempera-
Flowsheeting complete plants Understanding the effect of catalyst beds
(The four preheater isolation valves are ture varies between 826 and 840°F (441
Sulphuric acid
21 NORAM’s proprietary heat and mass bal- triple offset high-temperature valves). The to 449°C). It is important to note that l catalyst price; controllers. Based on the dynamic simu- Industrial sulphuric acid plants often only
ance routines for sulphuric acid systems increase in bed temperature after preheat- the target temperature (as per NORAM’s l two year warranty on conversion; lations, specific recommendations were have converter temperature measurements plant simulation
22 are effectively used to simulate a variety ing (for beds 2, 3 and 4) provides higher converter design) for this particular bed is l pressure drop warranty at start-up and given to implement automatic temperature and rarely have the possibility to regularly
of plant systems. Accurate prediction margin over the sulphuric acid dew point 832°F (444°C). All parts of bed 4 would after six months; control for converter beds 3 and 4. The con- measure gas concentrations on the inlet
23 of performance and physical properties and reduces the chances of acid conden- receive gas within 10°F (5°C) of the target l cost of blower power required to over- trolled variable is the bed inlet temperature and outlet of each bed. In the few cases
allow for the complete understanding sation, corrosion and fouling. temperature. come the catalyst pressure drop over a at the top of the catalyst for each bed. The where temperature measurements are
of the plant unit operations and system period of ten years. auxiliary quench air blower discharge pres- available in the beds, the exact catalyst
24 Design of inter-bed gas mixing device Catalyst evaluation
integration. sure and vent to atmosphere can be kept height above that measurement is often

25 In this case, a plant utilised a cold air quench In this case a client asked NORAM to It was found that the catalyst with the high- on manual control for periodic adjustment. unknown. Needless to say, the tempera- SULPHUR

ISSUE 375
Catalyst preheating system in between beds 3 and 4 to cool the process review the technical and commercial quo- est conversion, and the lowest operating ture and conversion profiles down through
The plant preheating system was re-engi- gas. NORAM modified the mixing strategy to tations from three major catalyst vendors. pressure drop had the lowest cost to the Operator training the converter catalyst beds are unknown
26 neered, specifically to improve the preheat- simplify the equipment design. NORAM devel- Best efforts were made to ensure that all client over a period of ten years (on a net Operating, maintaining and upgrading a to the operator of the plant, who can only
ing of the catalytic converter. The capacity oped computational fluid dynamics (CFD) vendors worked using the same assump- present value basis). It was noted that sulphuric acid plant is a challenging task. It assess performance based on the outlet MARCH-APRIL 2018
27 of the preheater was reviewed, and hot gas models to design an adequate gas mixing tions to be able to make a balanced pressure drop was an important factor in requires knowledge about many disciplines temperatures. Using computer models,
lines were directed to each of the catalyst device. This is important to ensure that the assessment of the different proposals. the comparison of the three proposals. The that is difficult to convey to newcomers to however, allows the temperature and con-
28 beds to ensure adequate preheating is inlet gas to bed 4 has a uniform temperature, A technical evaluation was made based final selection, purchase and installation the industry. In addition, experience from version trends to be followed in great detail.
achieved in all parts of the converter. The and uniform O2 and SO2 concentration. This on the following performance indicators: of the catalyst was made by the client, and senior engineers and operators is difficult The models can be employed to assess the
29 equipment was designed and a dynamic design allows for adequate conversion of SO2 l conversion per bed; they decided to source the catalyst from to transfer within an organisation. NORAM effect of low activity catalyst, or to see how
simulation was developed to identify the and is important during start-up as well as l outlet temperature per bed; a vendor based on other considerations. offers a systematic training course that uti- best to employ caesium catalyst.
30 improvements obtained. normal operation. l pressure drop per bed (gives pressure lises knowledge management techniques
Based on the results of the simulation ANSYS Software R15.0 was utilised to drop estimate of grids and ceramics Dynamic simulations for gas to train managers, engineers and opera- Effect of low temperature activity
31 (Fig. 6), it was concluded that for the exist- carry out the CFD simulations. The fluid is separately);
temperature control tors based on the core knowledge already Written as a chemical reaction, the catalyst
ing design, if all the hot gas from the pre- modelled as 3-Dimensional, non-isother- l emissions in ppm. existing within the plant personnel, and oxidation of SO2 to SO3 looks rather simple; Southbank House, Black Prince Road
32 heater is fed to bed no.1 only, achieving a mal flow. The following parameters are NORAM developed a dynamic simulator enhanced by state-of-the art know-how on
SO2(g) + ½ O2(g) SO3(g) London SE1 7SJ, England
catalyst temperature of 800°F (427°C) is evaluated for each CFD case to identify A commercial evaluation was made based using Aspen Dynamics software to con- sulphuric acid manufacturing, including the Tel: +44 (0)20 7793 2567
33 not possible for beds 3 and 4. the best inter-bed quench system design: on the following: firm the operability of the gas temperature presentation of simulation results. ∆H° ≈ -94 MJ/kg-mole
Fax: +44 (0)20 7793 2577

33 www.sulphurmagazine.com Sulphur 375 | March - April 2018 Sulphur 375 | March - April 2018 www.sulphurmagazine.com 33 Web: w ww.bcinsight.com
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1

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2 Sulphuric acid plant SimulatorS

3
■ CONTENTS
4
5 Fig. 8: Development within SO2 converter predictions both 390°C and 420°C. The curves illus- What’s in issue 375
trate very well the effect of increasing the
inlet temperature, the reaction initiates
6 much faster and less catalyst is needed

7
to bring the reaction close to equilibrium. ■ COVER FEATURE 1
One consequence of the increased inlet
temperature is, however, lower maximum
8 conversion due to lower equilibrium conver- Middle East
Limited models
Comprehensive models sion, which is not usually desirable. Sulphur
9 l Extensive mapping of
l common
areas
full range
• custom models for best fit
l Effect of catalyst deactivation Conference,
10 Introduction mapped
l Based on
l models for dynamic response Simulation models can also be used to Abu Dhabi
of computer obtain a better understanding of how deac-
literature
simulations
11 tivation of the catalyst will affect conver-
sion, and how it can be countered.
Rules of thumb
12 The performance of a full bed loaded ■ COVER FEATURE 2
with old or inferior catalyst is presented
together with the reference loading in Fig.
13 Source: Topsoe
North Africa’s
12. At the lower inlet temperature the
14 inferior catalyst is unable to achieve the phosphate industry
Fig. 9: Reaction rate, 14% SO2, Fig. 10: Limitation in a catalyst bed, required conversion rate due to a dramatic
11% O2, inlet temp. 394°C temperature profile reduction of ignition capability. The conse-
15 quence of the low reaction rate is that the
main part of the catalyst bed is utilised to ■ COVER FEATURE 3
16 580 catalyst achieve a temperature where the reaction
temperature, °c

equilibrium
limited
reaction rate

530 limited ignites. The graph also shows that increas-

17 480 ing the inlet temperature can provide a
SRU combustion
430 solution to the problem, as even the infe- challenges
18 390 rior catalyst is sufficient to reach equilib-
380
depth in bed rium. The higher inlet temperature comes
19 depth in bed at a cost of lower total bed conversion.
Source: Topsoe Source: Topsoe Fig. 12 also shows the importance of ■ COVER FEATURE 4
20 installing good fresh make-up catalyst in
the top of the bed after screening. Installa-
Sulphuric acid
21 However, trying to optimise it for vari- as high SO3 concentration and high tem- tion of low activity catalyst will result in lit-
ous gas conditions, inlet temperatures and perature bring the reaction close to equi- tle, no, or potentially even negative impact plant simulation
22 catalyst activities is no simple matter. librium. on bed performance, since the catalyst
The reaction is exothermic, which The limitations at the bottom and top of is installed in the most crucial location
23 means that the equilibrium will be pushed the bed are not the same, the low reaction where catalyst activity and low tempera-
in favour of SO3 formation, if the tempera- rate in the beginning of the bed is limited ture performance has the highest impact
ture is decreased. On the other hand, the by the efficiency of the catalyst at the given on reaction rate.
24
rate of reaction will increase if the inlet inlet conditions, in particular temperature.

25 temperature is increased, hence inlet tem- The reaction simply does not start fast Effect of Cs-promoted catalyst SULPHUR

ISSUE 375
perature becomes a balance between striv- enough, due to too low inlet temperature Another way to overcome low tempera-
ing for higher conversion at the bed outlet and/or insufficient catalytic activity. In ture limitation is by installing caesium-
26 and maintaining sufficient reaction rate in this region catalyst activity is exception- promoted catalyst in the catalyst bed, the
the top part of the bed. ally important. Installation of even a small same arguments as used above apply to MARCH-APRIL 2018
27 A typical reaction rate through a cata- amount of good fresh catalyst or high per- the use of caesium promoted catalyst. It
lyst bed is illustrated in Fig. 9, where the formance caesium catalyst in this crucial is again important to select a catalyst with
28 first part of the curve shows a slow start region will significantly boost ignition capa- a good low temperature activity to counter
with a very low reaction rate, and thus very bility and overall performance of the entire the low temperature limitations in the first
29 low temperature increase, correspond- bed. In the last part of the catalyst bed, part of the bed.
ing to minor SO2 oxidation to SO3, until it the reaction rate is limited by the equilib- The effect of installing a top-layer of
30 reaches a certain point where the reaction rium of the conversion reaction. caesium-promoted catalyst is well illus-
rate increase rapidly. After reaching the A typical temperature profile through trated in Fig. 13, where the reaction rate
31 maximum reaction rate, the reaction rate a catalyst bed is illustrated in Fig. 10, increases faster and reaches the same
is decreased again due to the increasing which also illustrates in which temperature high reaction rate earlier in the bed. The Southbank House, Black Prince Road
32 contribution of the reverse reaction ranges the reaction rate is limited. outcome is that it is possible to maintain London SE1 7SJ, England
Fig. 11 shows the temperature profile the same conversion rate with a lower cat- Tel: +44 (0)20 7793 2567
SO2(g) + ½ O2(g) ← SO3(g)
33 when operating at an inlet temperature of alyst volume installed.
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2 Sulphuric acid plant SimulatorS Sulphuric acid plant SimulatorS

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4
5 Fig. 11: Effect of increasing the Fig. 12: Effect of ageing and inferior Fig. 13: Effect of a top layer of Fig. 16: Effect of purge time and Fig. 17: Effect of temperature on is crucial for desorption of SOx from the What’s in issue 375
inlet temperature from catalyst Cs-promoted catalyst temp. on catalyst sulphur content start-up emission catalyst because it affects both the rate
390°C to 440°C of desorption and minimum the degree of
6 2,000 sulphatisation achievable for the catalyst.
100

normalised free sulphur

■ COVER FEATURE 1

So2 emission, ppm

temperature, °c temperature, °c temperature, °c no purging Fig. 16 shows the effect of different tem-

content in catalyst, %
7 VK59 and VK38 75 purging at 350°c 1,500
no purging peratures and purging time on the catalyst
580 580 sulphur content, while Fig. 17 shows how
580 1,000
8 VK38
50
purging at 450°c the different purge temperatures affect the Middle East
530 530 25
530 500 purging
at 350°c
emission during the subsequent start-up. Sulphur
9 purging at 450°c From Figs 16 and 17 it is apparent that
480 480 480 0
0 2 4 6
0
0 0.5 1 there is much to gain in terms of reduced Conference,
time since introduction of feed gas, hours
10 430 430 430
time since stop of feed gas, hours start-up emissions by spending some more Abu Dhabi
time and money on a longer or warmer
11 380 380
depth in bed
380
depth in bed
Source: Topsoe Source: Topsoe purge of the catalyst when shutting down.
depth in bed What is achievable in practice is of course
12 Source: Topsoe Source: Topsoe Source: Topsoe plant specific, but even a smaller improve- ■ COVER FEATURE 2
concepts for handling these conditions is Effect of purging ment may be what it takes to get the emis-
often not practically possible. However, As a result of the ability of the sulphuric sion peak below the limit.
13 North Africa’s
Revealing plant limitations through Due to the vast number of different combi- authorities and proactive plant owners, simulation models allow new concepts to acid catalyst to absorb or desorb SOx, the
14 plant simulations nations imaginable, and the varying require- and some plants have regulatory emis- be tried, without any risk to the surround- way the catalyst is purged during shutdown Effect of Cs-promoted catalyst on start-up phosphate industry
ments between different beds, it is all but sion limit requirements during the start- ings, or being forced to stop the start-up will have a profound effect on SO2 and SO3 For practical reasons, purging warmer or
Robust plant simulations allow fast evalu- impossible to capture this through design up period. The general challenge for plant process. Also important is the ability of emission when the plant is started back longer during shutdown is not always an
15 ation of how a new plant concept or cata- guidelines alone. Good simulation models operators is to shut down and start up as the simulation models to quickly show the up. A well purged catalyst bed will reduce option. It has long been known that cae-
lyst loading would perform. It can also are necessary to ensure both cost effective fast as possible with a minimum fuel con- effect of different process settings. Getting issues with desorption of SO3 during start- sium catalyst has an effect on start-up SO2 ■ COVER FEATURE 3
16 help understanding the effect of different and reliable catalyst loadings or plant design. sumption and with minimum SO2 and acid the same data from real life tests might up, and have a significant SOx absorption emissions. How big the effect is, and its
feed gas conditions overall SO2 conversion mist emissions. take multiple trials, and as with all real life capacity which will reduce the emission effect at the specific plant or condition,
17 and plant operability. For example, Fig. 14 Transient simulations The dynamic behaviour of the cata- testing, the conclusions would likely be peak often seen during start-up. The tem- however, is not known. With dynamic simu-
SRU combustion
illustrates how single absorption, double During steady state, or near steady state, lytic converter is of major importance in less clear due to process variations. perature of the catalyst during the purge lation models, this can be investigated. In challenges
18 absorption and triple absorption performs conditions, a well maintained sulphuric these situations. Firstly, the sulphuric acid
with the same gas conditions and catalyst acid plant with a state of the art catalyst catalyst requires certain minimum tem- Fig. 18: Effect on start-up SO2 Fig. 19: Hot standby time permissible Fig. 20: Industrial start-up data using
19 loading. loading in the converter can achieve very peratures to oxidise SO2 efficiently to SO3. emission of using caesium with differential loadings standard catalyst compared to start-
Simulation models are also very use- low SO2 emission levels. Under transient Secondly, the catalyst has a significant catalyst (VK69) in Bed 4 up performance using VK69* ■ COVER FEATURE 4
20 ful in determining the necessary catalyst conditions, however, the same low emis- absorption capacity for sulphur oxides,
30

extra hot standby time, %

1.0 *Showing similar performance, despite using a total
loading when designing for different gas sion levels cannot easily be achieved. Dur- which must be taken into account as it
Sulphuric acid

emission, normalised
of 30°C lower bed temperature for beds 3 and 4.
25
21 compositions (see Fig. 15). ing start-up, shutdown, feed change, and affects heat evolution and SO2 conversion 0.8 VK38
1/3 VK69 1,200
As indicated in Fig. 15, the changes in process upsets, unfavourable operating during transient operation. 0.6 VK69 20
15
standard catalyst plant simulation

emission, ppm
22 the catalyst loading necessary to achieve a conditions of the plant typically lead to Due to the risks involved, both to the 0.4 10
800 VK69
actual
fixed conversion requirement changes con- increased emissions. These emissions are environment and people in or close to the 5
0.2 400
23 siderably as the gas composition changes. attracting more attention from regulatory plant, experimenting with different new
0.0 0 simulated
0 0.2 0.4 0.6 0.8 1 0 0.2 0.4 0.6 0.8 1 0
Fig. 14: Simulated conversion and emission of three Fig. 15: Relative catalyst loading required to achieve 99.9% fraction VK69 0 1 2 3 4 5 6 7
24 different plant configurations conversion at three different gas conditions
time, hours
time, hours
Source: Topsoe Source: Topsoe Source: Topsoe

25 SULPHUR

26
100

99
325 ppm
40 ppm Fig. 21: Simulated and industrial
start-up data with VK69 in the
Fig. 22: Predicted start-up emission
when using standard catalyst
Fig. 23: Effect on the start-up SO2
emission of using caesium catalyst
ISSUE 375
bed 1
bed 1 bed 1 final bed showing good agreement compared to actual emission when (VK69) in bed 4* MARCH-APRIL 2018
27 98 between the two using caesium catalyst in the final bed
bed 2
conversion, %

bed 2 bed 2
28 97 1

emission, normalised
standard catalyst 0.8 VK38
bed 3 bed 3 bed 3 1,200
VK69 1/3 VK69
96 1,200 0.6
29 bed 4 bed 4 bed 4
emission, ppm
800 predicted 0.4
VK69

emission, ppm
95 actual data 800 0.2
30 S-burner Zn-roaster Cu-smelter 400
400
0
0 0.2 0.4 0.6 0.8 1
94 7,910 ppm S-burner Zn-roaster Cu-smelter simulated values time, hours
0 actual
31
Gas (So2/o2) 10.5/10.5 7.0/9.0 15.0/13.9
93 relative loading 100% 133% 80% 0 1 2 3 4 5 6 7 0 * When the catalyst has been purged at
Sa da ta Emission 125 ppm 80 ppm 195 ppm time, hours 0 1 2 3 4 5 6 7 450°C for 30 min during shutdown. Southbank House, Black Prince Road
production 1,000 t/d 1,000 t/d 1,000 t/d time, hours
32 London SE1 7SJ, England
Source: Topsoe Source: Topsoe Source: Topsoe Source: Topsoe Source: Topsoe
Tel: +44 (0)20 7793 2567
33 Fax: +44 (0)20 7793 2577

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5
Fig. 18, the effect on the emission peak two effects can be combined for even how: smart equipment, smart process and What’s in issue 375
of using one-third of a bed or a full bed of greater SO2 emission reduction during smart site. Outotec is applying simulations
caesium promoted catalyst (VK69) in bed start-up. Fig. 23 shows the effect of using to these layers, ensuring increased plant
6 4 is shown when starting up after each bed different catalyst loadings in bed 4 when safety, optimised plant operation and up-
APRIL 23–25, 2018
7
has cooled down 60ºC. also having purged the catalyst at 450°C to-date training methods at customer sul- ■ COVER FEATURE 1
It turns out that for this 3+1 DA plant, for 30 minutes during shutdown. phuric acid sites.
the emission during start-up cat be cut by Figs 18 and 23 are very similar in Outotec has identified three main levels
8 Middle East
half by replacing one third of bed 4 with
VK69 and by 75% when using a full bed.
appearance, meaning that the relative
improvement of using a caesium catalyst
for simulation applications:
l Equipment level
Delve into sulphur and sulphuric acid trends Sulphur
9 If the current emission is not an issue,
but rather the time the plant can be
in bed 4 is similar regardless if the cata-
lyst has been purged hot or cold during
l Process level
l Site level
while discovering the rich history of Philadelphia Conference,
10 allowed to cool off or the time available to the shutdown. It is however important to In another dimension, two different cases
TSI’s Sulphur World Symposium is an annual conference that attracts international sulphur Abu Dhabi
heat the plant during start-up, using a cae- remember that the peak for the standard for simulations can be identified:
11 sium catalyst may also be a good solution. catalyst is far lower in Fig. 23 than in Fig. l Design and engineering, using simu- and sulphuric acid industry leaders from over 25 countries. TSI will provide two days of
Fig. 19 shows the relative time a theoreti- 18, compare the curves for 450°C purge lations to enhance quality of product
specialized speakers and networking events. With over 125 principal sulphur delegates
12 cal 3+1 DA plant can be allowed to cool and no purge in Fig. 17. design ■ COVER FEATURE 2
down with different loadings. l Operation and commissioning support, expected, this truly is a distinguished industry event.
13 From Fig. 12 it can be seen that a third Outotec smart digital applications where simulations play an essential role
North Africa’s
of a bed of caesium catalyst in bed 4 of
phosphate industry
Presentations
a 3+1 DA plant can compensate for 10% Outotec has in recent years intensified its This classification structure is illustrated in
14 longer cool down and that a full bed of cae- effort in developing models to accommo- Fig. 24. On the left side, design and engi-
sium catalyst can compensate for a 25% date the increasing customer needs for neering approaches are illustrated, catego-
15 longer cool down with no increase in emis- simulation based offerings10. rised with respect to equipment, process The Global Energy Outlook
sion. This improvement in start-up perfor- Besides using simulations to support and site level. Giving one example, Outo- ExxonMobil Oil Corporation ■ COVER FEATURE 3
16 mance of the plant is in addition to the process development, plant design, equip- tec’s enhanced process simulation capa-
Making American Great Again: Implications for the U.S. and Global Economy
improvement in steady state conversion, ment design, etc., simulations nowadays bilities as well as detailed information on
17 which in most cases is the main reason form the basis to improve plant operational heat transfer and heat recovery have led to John Urbanchuk, Delaware Valley University SRU combustion
for adding a caesium layer in the final bed. safety as well as to achieve increased oper- the development of the HEROS® system, a China’s “One Belt, One Road” initiative transforms global supply chains challenges
18 In the case of a running industrial plant, ational performance. These efforts apply not proprietary process module used in mod-
Dr. David Meyer, Olin Business School, Washington University in St. Louis
simulations indicate that the extra activity only to the sulphuric acid plant, but also to ern sulphuric acid plants to increase heat
19 of the caesium catalyst could compensate the gas cleaning and upstream metallurgi- recovery11. Consideration of the advanced IMO 2020: A Sea Change is Coming
for a total reduction in inlet temperature cal process. For a fully digital supported levels of simulation based process and site Ralph Grimmer, Stillwater Associates ■ COVER FEATURE 4
20 to the two last beds of 30°C, 20°C in bed plant operation, Outotec is also developing design, it is typical to simulate several dis-
Caprolactam Market Review
4 and 10°C in bed 3. The emission peak in-house process plant training simulators, creet, but interdependent, plants in combi-
Mark Victory, ICIS Sulphuric acid
21 using the caesium catalyst and lower inlet ensuring high quality operator training. nation, up to a full site assessment. In doing
temperatures is the same as before, but Outotec’s simulation philosophy com- so, correct dimensioning of several process
The Outlook for Phosphate Markets: What’s Next? plant simulation
22 the average emission during the complete prises three smart layers of process know- steps ensures combination of all plant sec-
Andy Jung, The Mosaic Company
start-up period is lower, see Fig. 20.
23 After the caesium catalyst has been Fig. 24: Outotec simulation models are used at different levels in design process Global Sulphur and Sulphuric Acid Market Outlook
installed, the emission with the lower inlet as well as in various digital operational support systems Claira Lloyd and David Tonyan, Argus Media
temperatures turns out to be very similar
24
to that predicted, albeit with somewhat Smart design & engineering Operation & commissioning
25 broader peak (see Fig. 21). SULPHUR
Registration discounts available!
ISSUE 375
Finally, the dynamic models can be Proprietary equipment design Smart equipment
eQUIPMeNT

l detailed design tools and simulation l health grade assessment of equipment

used to predict what the start-up emission
26 would have been, if the same inlet tem- for equipment dimensioning l Example: porS Contact TSI for details
l Example: converter tower, hEroS® l advanced control
peratures had been used with the standard MARCH-APRIL 2018
27 catalyst. In Fig. 22, the predicted start-up Visit The Sulphur Institute’s website to learn more. +1 202 293 9305 @TSISulphur
emission using standard catalyst is com- Process simulation Smart process www.SulphurInstitute.org/Symposium18 kkurowski@sulphurinstitute.org
PROCeSS

28 pared with the recorded emission when

l heat and mass balance l process advisor, monitoring & optimisation
l Flowchart, e.g. hSc l training simulator
using caesium catalyst. The emission l development, design & dimensioning
29
l outotec pretium products
when using the standard catalyst is around
twice as high compared to when caesium
30 catalyst is used.
Site simulation
l Full site flowchart
Smart site
l multiple plant optimisation systems
Official Publication:
SITe

l outotec pretium products

31 Maximising start-up performance l manufacturing execution systems

Simulations show that the positive effects Southbank House, Black Prince Road
32 of hot purging during shutdown does not Media Sponsor: London SE1 7SJ, England
nullify the effect of installing caesium pro- Source: Outotec
Tel: +44 (0)20 7793 2567
33 moted catalyst in the final pass, but the
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4
5
tions at site working together as intended. Fig. 25: Gap analysis between plant simulation and measured plant data in real time Fig. 26: Simulation accuracy for sulphuric acid flowchart simulation are mean values over a certain time range. What’s in issue 375
Applying smart design and engineering pro- In summary, the accuracy of the simula-
cesses using simulation prevents oversized tion is very high with most values below 1%
6 as well as undersized equipment or plants Outotec (plant manufacturer) Real plant operation 4.0
error. However, the first converter stage
plant simulation Equipment level calculation 3.5
and thus allows Outotec delivery of up-to- outflow temperature shows deviations ■ COVER FEATURE 1

capacity, t/h
140
3.0
7 date plants without bottlenecks.
steam acid cross flow 120
between measurement and simulation of

error in %*
100
0 2.5
On the right side of the diagram, simu- So3 + So2 So2 more than 3%, thus requires further inves-
Middle East
module level calculation
2.0
8

capacity, t/h capacity, t/h

140
lation methods play an important role in 120 1.5 tigation. Such an error can either mean
Sulphur
100
digital supported equipment, processes or 0
1.0 that the model parameters are inaccurate
9 sites. Smart equipment uses detailed sim- sulphuric unit level calculation
or that the catalytic converter in the first
Conference,
pump
acid diluter
tank
140
120
unit level
plant level
0.5
ulation models on unit equipment, making 100 0.0 stage shows effects of aging.
10 Abu Dhabi
0
such equipment or process units intel- plant level calculation

co g to in

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ut

ab er to r in

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Advanced automation

capacity, t/h

ou

ou

er r ou

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heat

lay
140

co erte 3 o

te orb 4 o
ligent. As an example, Outotec has intro-

yin wer

ter ed 1

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4
te 1 la

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exchanger

er
120

fin sor tow

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d
we

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4
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100
11

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duced the Plant Operability Reliability and In addition to the simulation-based fault

ab er
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co rter

co rter
0

yin

b
ter

ter
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10 may 2015 20 may 2015 30 may 2015 10 June 2015

rb
ter
e

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dr

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Safety (PORS) system for sulphuric acid detection methods and operational sup-

nv

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nv

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dr

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nv

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real time process data

co
virtual plant simulator
■ COVER FEATURE 2

me e
c
co
12 plants11. A good example of this is the use port functions for the acid plant, Outotec

iat

al
accessible via dcS

d
calculates ideal operation
of PORS on the product acid cooler, where has recently strongly intensified its effort

er
er
int
int
mathematical models monitor the heat in advanced control and automated opti-
13 Gap analysis
comparison between ideal and real plant operation North Africa’s
transfer between acid and water side in *The error in % is calculated in Kelvin and related to the measurement misation methods for whole plant units.
14 order to allow an early leakage detection. With respect to a sulphuric acid and gas phosphate industry
Such simulation models integrate a deep Source: Outotec cleaning plant train, a strong improve-
process understanding, as well as detailed Outotec Pretium advisor ment of the operational stability was
15 equipment knowhow. The equipment gains
l plant operational support by advice or full automation
achieved by applying a fully automated
l closing the gap between theoretically possible and real plant operation
a certain degree of intelligence and con- l plant operation shifting towards ideal plant operation Fig. 27: RoasterOptimizer – expected exchangers is usually very high, however control and optimisation scheme to the ■ COVER FEATURE 3
16 nectivity and thus is considered smart long term reduction of emissions variances between simulated and meas- upstream metallurgical roasting plant.
equipment. Furthermore, smart equipment ured heat exchange can be for different Today, several customers operate their
17 can include advanced control algorithms to
Source: Outotec
manual operation reasons. For example, sudden rises in the roaster with Outotec’s RoasterOptimizer,
SRU combustion
ensure operational stability and enhance outotec pretium operation
gap between theory and measurements benefitting from increased throughput challenges
18 equipment performance. or even with defective equipment. The pro- tion trends. PORS was developed to guide are usually a sign of leakage, whilst long whilst maintaining product quality at a

emissions
Outotec’s smart processes are more cess integrity can thus be increased by and support plant operating personnel. term monitoring also allows for the detec- high level.
19 extensive and may well be a combination using Outotec training solutions. The system enhances situation awareness tion of fouling trends. The RoasterOptimizer is a multivari-
of a number of pieces of smart equip- On the level of smart sites, Outotec in case of potential operational problems able control and optimisation system, ■ COVER FEATURE 4
20 ment. Smart processes comprise Outotec is combining different features of both and challenges and thus allows a safer and roasteroptimizer
improvement
Simulation accuracy combining detailed simulation models
Pretium products, covering plant wide pro- smart equipment and processes over the more efficient handling of the process11. In order to achieve the required simulation with advanced automation concepts to
Sulphuric acid
21 cess advisor systems, monitoring and opti- traditional battery limits of single plants. What started as a safety related system accuracy required for both fault detection enhance the roaster operation. Besides
misation functionality12. Outotec Pretium Logically, optimisation of a process plant associated with heat recovery is currently algorithms as well as for operational sup- monitoring various variables of the roast- plant simulation
22 is a proprietary platform for development network can result in significant advantage being extended to a full plant operational port, various experts within Outotec are ing plant, the system also considers pro-
and implementation of digital products13. over individually optimised operations. simulation based support system, includ- plant throughput involved. Process experts are responsible cess variables of the downstream gas
23 Therein, simulations can form the basis Comparing such future plant concepts ing the gas cleaning and acid plant as well for bringing in process knowhow, flowsheet cleaning and acid plant. One of the results
for operational advice. Such advice is with classic plant operation, significantly as upstream metallurgical process steps Source: Outotec calculations, as well as plant wide calcu- of implementing the RoasterOptimizer for
presented to the operators, which can more measured process values are utilised such as the roasting plant. lation models and site experience. Equip- the complete process chain has been
24
improve the plant performance or reduce in the production process and evaluated The scheme of a gap analysis within the ment experts provide the required detailed security in ensuring that environmental

25 emission levels14, 15. Also on the process automatically and in real time than at most PORS-System is detailed in Fig. 25. Outotec not as expected. Such gaps can now be knowhow on single process units and emission values were not exceeded whilst SULPHUR

ISSUE 375
level, Outotec uses dynamic training simu- production sites today. Process plants are as process plant supplier has all relevant used in a number of different ways. catalyst experts ensure the accuracy of increasing plant capacity. Fig. 27 indicates
lators to train personnel who will ultimately generally handled by human operators, equipment and process simulation models If an operational issue is detected, detailed models regarding the chemical expected long-term results for environ-
26 operate the plants. Such training simula- who can only follow a certain number of as well as the experience in relation to the advice can be given to the operators in the conversion from SO2 to SO3 and H2SO4. mental factors when the plant is in opera-
tors are based on dynamic process simula- trends or a limited quantity of informa- material characteristics, long-term process form of precise information of which set- The simulation accuracy for tempera- tion using the RoasterOptimizer, clearly MARCH-APRIL 2018
27 tions. In contrast to the steady state high tion. Operating a plant with full digital sup- behaviour or conversion rates of catalytic point should be changed in order to bring tures in a sulphuric acid plant flowsheet demonstrating the advantage in terms of
fidelity process simulations used for pro- port allows for automated monitoring and reactions from SO2 to SO3, etc. the plant operation closer to the theoreti- simulation is shown in Fig. 26. Therein, reduced emissions.
28 cess design, dynamic simulation models supervision of all measured information16. The full simulation model results of pro- cal optimum. Optionally, such setpoints simulation results and plant measure- Table 2 shows operational effects and
utilise simplifications where required. How- In the following sections, operational case cess plant or plant site are compared to can be set automatically. Thus, the gap ments are compared. The error is given in benefits that can be measured over sev-
29 ever, such simulations are fully capable of studies of smart digital applications within the current readings from the distributed between theoretical and real plant opera- % and is calculated by eral months of operation.
reproducing transient plant performance Outotec plants are given. control system (DCS). On the simulation tion is minimised. The operation is thus A combination of digital tools for
30
31
and simulating the plant response to oper-
ator inputs. The dynamic training solutions
include the process control loops and thus
Outotec PORS-System
Outotec’s PORS system is a state-of-the-
side, the theoretical plant operation is
available, whilst the DCS measurements
show the current real time situation of the
improved, targeting the theoretically pos-
sible operation calculated by Outotec’s
mathematical simulations.
| γmeasured |
e= (γsim - γmeasured) ∙100 upstream metallurgical process steps (e.g.
feed preparation and roasting), as well as
downstream process steps (e.g. gas clean-
allow new operators to train without risking art monitoring and supervisory system. It process plant. A gap analysis compares Gaps can also be caused by fouling γsim is the respective simulated tem- ing, sulphuric acid production and hydro- Southbank House, Black Prince Road
32 the production process. Furthermore, train- is based on simulation models and mathe- the ideal or theoretical operation with the effects. Sulphuric acid plants have multi- perature value in K, while γmeasured is the metallurgical plant sections), reveals the London SE1 7SJ, England
ees can gain experience with fluctuating matical calculations and detects both short real time data and reveals where the pro- ple heat exchangers of different types. The respective measurement value in K, cap- full potential in the operation of today’s Tel: +44 (0)20 7793 2567
33 process conditions, feed/blend variations term process failures and long term devia- cess operation or operating conditions are precision of mathematical models of heat tured by the DCS. The DCS measurements production sites. In the given example, the
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Combustion challenges
Table 2: RoasterOptimizer benefits References What’s in issue 375
5 1. Gable, Betz, and Maron, “Phase equilibria of
the system sulphur trioxide – water”, Journal
6 Feed material preparation with  addition of waste streams and/or low grade of American Chemical Society, 72 (1950).

in the reaction furnace

increased blend flexibility concentrates, lowering production cost 2. Perry’s chemical engineer’s handbook 7th

7 Roaster plant availability and  through process stabilisation, reduced stress on ed Don W. Greed ed, McGraw Hill (1997). ■ COVER FEATURE 1
capacity increase plant and equipment 3. Thomson J. and Lee H.: “An alternative
method to model properties in Aspen Plus”,
8 Acid plant environmental
improvements
 lowering SO2 emissions, reducing bottlenecks
Aspenworld 2000. Middle East

4. Lee H.: “Sulphuric acid plant simulators –
Sulphur
9 Leaching efficiency increase through higher calcine product quality, lowering valuable tool to improve design and operation
production cost in hydrometallurgical plant section of existing operations”, written for Sulphur The overall performance of the modified Claus process is, for a large part, determined by the Conference,
(Feb 2018).
10 Source: Outotec 5. Lee G., Cooper G., Mahecha-Botero A. Niko- design and operation of the main burner and reaction furnace. In this article Duiker examines Abu Dhabi
laisen K.: “Steady state and dynamic simula-
11 tion of sulfuric acid plants”, AICHE Clearwater some important performance aspects of the reaction furnace; Siirtec Nigi reports on the
integration between the RoasterOptimizer, trained, giving current and future operators Conference, Florida (2014).
benefits of its improved SRU thermal section; Blasch discusses its latest developments for
12 stabilising and optimising the fluidised bed a full understanding of critical issues, such 6. Mahecha-Botero A., Morrison B., Juzenas G.
■ COVER FEATURE 2
roaster, with PORS, monitoring and super- as heating rates. Outotec dynamic train- et al: “Upgrading a sulphuric acid plant: Proj- SRU reaction furnace internals; and Jacobs introduces Temp-Protect, a useful tool for better
ect execution strategy and performance evalu-
13 vising the full acid production process, ing simulators are configured so that the
ation”, AIChE Clearwater Conference, Florida temperature monitoring in the reaction furnace. North Africa’s
results in a combined optimisation of the trainer can always playback stored training (2016).
14 full production chain of roasting – gas sessions to discuss operational failures or 7. Granroth M.N.R., “Simulation models for sul- phosphate industry

T
cleaning – sulphuric acid – leaching plant. exceptionally good training performances. furic acid plants”, written for Sulphur (Feb he desulphurisation of fossil fuels
Fig. 1: Sulphur concentration profile in the reaction furnace relative to equilibrium
This represents leading edge plant perfor- Customer feedback on dynamic training 2018).C. Frandsen, A. Larsen, “Effect of produces large amounts of hydrogen
15 mance through simulation and digitalisa- simulators are constantly positive, highly inferior and ageing catalyst”, SAIMM 5th Sul- sulphide (H2S) gas, which is mostly
according to the classical two-step mechanism
phur and Sulphuric Acid 2015 Conference.
tion and is a significant step towards fully appreciating the opportunity to train per- treated in the modified Claus process to ■ COVER FEATURE 3
16 automated production processes, which sonnel without operational risk.
8. Sørensen P., Møllerhøj M., Christensen
recover elemental sulphur. In the thermal
K.: “New dynamic models for simulation of 1½ S2 + 2h2o → 2h2S + So2
can be expected in the future. stage of the Claus process H2S gas is par- reverse claus
17 Worldwide trend towards digitalisation
industrial SO2 oxidation reactors and wet gas
sulphuric acid plants”, J. Chem. Eng. 278 tially combusted with air by a main burner, reaction SRU combustion
Dynamic training simulators Besides roaster, gas cleaning and acid p.421-429 (2015). resulting in a flame with a temperature in the challenges
18 As described briefly above, a further typical plants, Outotec’s effort on digital opera- 9. Sørensen P. and Christensen K.: “Under- range of 900 to 1,400°C. The thermal stage chemical equilibrium

sulphur concentration
field of application for simulations are train- tional plant support is currently intensify- standing dynamics and emissions during is crucial to the overall performance of the
19 ing systems. Based on dynamic full plant ing on various processes. As an example,
sulphuric acid converter startup”, Sulphur
2015 – 31st Annual Conference of Sulphur
modified Claus process, not only producing
simulations, such training systems allow dynamic training simulators for waste-to- and Sulphuric Acid, (2015). the majority of the sulphur but also ensuring ■ COVER FEATURE 4
20 trainees and operators to familiarise with energy power plants are currently used for 10. Haus S., Grünig J., Runkel M., Bräuner S., the destruction of impurities (in cases where 2h2S + So2 → 1½ h2S + 2h2o
the plant operation in a safe environment. operator training prior to plant commission- Hammerschmidt J. and Bartlett C.: “Simula- hydrocarbons or ammonia must be handled)
combustion zone Sulphuric acid
21 Outotec utilises dynamic training simula- ing. Advanced control systems, optimisa- tions – improving plant safety and increas- and minimising undesirable by-products such reaction zone
tors amongst others to train sulphuric acid tion systems as well as advisory solutions ing operational excellence in sulphuric acid as carbon disulphide (CS2). plant simulation
plants”, written for Sulphur (Feb 2018).
22 plant operation and roaster plant opera- are used in various process technologies
11. Kemmerich M. and Storch H.: “Process heat
Mixing plays a significant role in all of
tion. Considering the roaster dynamic train- or are currently in a final development these functions of the thermal stage, and reaction furnace residence time
recovery and digitalisation in sulphuric acid
23 ing simulator as an example, the training stage prior implementation for different plants,” in 3rd International Symposium on high-intensity H2S burners are especially Source: Duiker
system is used prior to the commissioning process technologies. Innovation and Technology in the Phosphate effective in creating the conditions in the
of a new plant. Thus, new operators that The worldwide trend towards digitali- reaction furnace (RF) that ensure a proper
24 Industry (2016).
12. Missalla M., Perander L., Haus S., Anastasijevic
have no real experience with the roaster sation and fully automated process plant functioning of the Claus process1. This mechanism predicts that, after thermal stage of the Claus unit than would
N. and Horn S., “How digitalization can further
25 operation highly welcome the opportunity operation can no longer be discounted the combustion stage (step 1), the sul- be predicted even by the equilibrium of the SULPHUR

ISSUE 375
improve plant performance and product quality
to train in a close to realistic environment. and Outotec has already laid the foun-
– Outotec pretium advisory tool for alumina cal- Sulphur recovery in the phur concentration steadily rises until it Claus reaction (2) at the observed furnace
Familiarisation with typical process behav- dation for future plant operations. The approaches its equilibrium value in the conditions. Detailed measurements of the
26 iour, but also with operational challenges potential for a fully autonomous plant
cination,” in TMS: Light Metals 2018 (2018). thermal stage Claus reaction (step 2), as shown in Fig. 1. gas compositions then indicate that the
13. “Outotec Pretium digital solutions,” Online:
(upset process conditions), occurs before operation is just a matter of time and https://www.outotec.com/explore/digitali- The classical way to represent the chemi- In this scenario, mixing in the reaction fur- sulphur concentration in the reaction fur- MARCH-APRIL 2018
27 the real plant is in operation. The trainees then operating companies can fully profit zation/outotec-pretium-digital-solutions/. cal conversion of H2S to sulphur in the nace merely facilitates the combustion nace approaches its equilibrium value from
learn typical plant delay times and control- from the possibilities of digitalisation, 14. Haus S., Mehl S. and Lagerstedt A.: “Optimiz- reaction furnace is by a two-step reaction step and the approach to Claus equilibrium above (see Fig. 1), and not from below as
28 ler behaviour but also have the option to after fully considering all the corporate
ing iron ore agglomeration plant performance
mechanism: in the first step, oxygen reacts by bringing the reacting species together. would be the case if the chemistry in the
– Outotec’s solutions for plant monitoring and
speed up the simulation (up to 50 times implications therefrom. High availability, sustainable operation,” in METEC, Düsseldorf,
with one third of the H2S feed to produce The RF chemistry is, in fact, much more reaction furnace follows the classical two-
29 that of real time) to understand long term high throughput whilst maintaining prod- (2015). sulphur dioxide (SO2) and, in the second complex than indicated above. Figs 2-5 step mechanism described above.
process reactions without a long waiting uct quality parameters as well as emis- 15. Missalla M., Perander L., Haus S. and Anas- step, the SO2 reacts with the remaining illustrate some of the bulk chemistry tak- An explanation for these observations is
30 time. Further learning effects are related sions and economically optimised plant tasijevic N., “Further optimization of product two thirds of the H2S to produce sulphur ing place in the reaction furnace. The found in the special working principle of the
to variability of fuel source, challenges operation will be the key future drivers. quality and plant performance in the calci- according to the Claus reaction. mixing and flow patterns induced by the high-intensity H2S burner. Full-scale simula-
31 in relation to fluidised bed operation and The proper use of detailed simulations nation process by utilizing digital tools,” in
ICSOBA, (2017). H2S + 1½O2 → SO2 + H2O (1)
high-intensity H2S burners seem to affect tions of the burner/RF combination using
solids handling, but also with respect to for full flowcharts, dynamic plant simula- the path that the chemistry takes in the techniques of computational fluid dynamics Southbank House, Black Prince Road
16. Haus S., Binder C. and Stefan T.: “Digitali- Combustion (step 1)
32 failure scenarios or how to handle plants tions, equipment and plant detail simula- zation of metallurgical process plants in the reaction furnace. This is supported by (CFD) in combination with detailed chemi- London SE1 7SJ, England
with defective or worn-out equipment. Start- tions will form the basis for such a digital future,” Heat Processing, vol. 14, pp. 109- 2H2S + SO2 = ½S2 + 2H2O (2) field data2 which show that significantly cal reaction modelling show rapid, yet Tel: +44 (0)20 7793 2567
33 up and shut-down procedures can also be optimisation process. n 115 (2016). Claus reaction (step 2) higher sulphur yields are obtained in the well-controlled mixing and simultaneous
Fax: +44 (0)20 7793 2577

44 www.sulphurmagazine.com Sulphur 375 | March - April 2018 Sulphur 375 | March - April 2018 www.sulphurmagazine.com 44 Web: w ww.bcinsight.com
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5 Fig. 2: Sulphur formation in the reaction furnace Fig. 3: Additional paths to sulphur formation Fig. 6: Gas temperature Fig. 7: Oxygen depletion What’s in issue 375
air
combustion zone
6 acid gas acid gas air

7 h2S + 1½o2 So2 + h2o h2S partial

H2S oxidation
h2S ■ COVER FEATURE 1
hydrogen oxygen sulphur water ½o2 ¼o2 oxygen
oxygen
8
sulphide
air
dioxide
acid Middle East
acid gas
gas h2o
sulphur ½h2o water acid
Sulphur
9 water
½h2 hydrogen gas
reaction zone
H2S cracking SO2 reduction main burner
mixing
chamber
main burner mixing Conference,
10 2h2S + So2 1½S2 + 2h2o h 2S 2h2o So2 reaction furnace
chamber
Abu Dhabi
hydrogen sulphur sulphur water h2
11 sulphide dioxide acid gas hydrogen 2h2 sulphur dioxide reaction furnace
Source: Duiker Source: Duiker

12 Source: Duiker Source: Duiker

■ COVER FEATURE 2
Fig. 8: Reaction furnace sulphur formation Fig. 9: Reaction furnace sulphur dioxide formation
13 Fig. 4: Ammonia destruction Fig. 5: Hydrocarbon destruction North Africa’s
14 Source: Duiker Source: Duiker
air air
reaction furnace
phosphate industry
nh3 + o2 → ½n2 + 1½h2o ch4 + 2o2 → co2 + 2h2o

15 nh3
CH4 conversion
cS2
CS2 conversion
co2
ch4
ammonia ½So2 ½h2o carbon carbon acid ■ COVER FEATURE 3
16 sulphur dioxide water methane
disulphide dioxide gas
acid gas

17 sulphur 2h2S So2 SRU combustion

sulphur main mixing
hydrogen sulphide
air
hydrogen
sulphur dioxide
burner chamber challenges
18 ½n2 ½h2S o2 sulphide main burner mixing journey
+ air
nitrogen oxygen reaction furnace
h2o
19 ammonia conversion water H2S oxidation
2h2o 2o2
water oxidation
oxygen
Source: Duiker Source: Duiker ■ COVER FEATURE 4
20
Sulphuric acid
21 reaction of H2S with both the flue gases which appears to be followed by further of the chemistry in the reaction furnace, Theoretical destruction efficiency and H2S and sulphur species in the combustion CH4 + 2S2 → CS2 + 2H2S (7)
already present in the reaction furnace and sulphur formation by the reduction of SO2: which may also be crucial factor in other
kinetic limitations zone of the reaction furnace and that only
CH4 + H2O → CO + 3H2 (8)
plant simulation
22 the oxygen introduced into the combustion
SO2 + 2H2 → ½S2 + 2H2O (6)
aspects of the RF performance. small amounts of hydrocarbons and NH3 are
zone of the reaction furnace. Figs 6-9 show Thermodynamic calculations clearly show that converted by direct reaction with oxygen. where H2S is subject to dissociation via
23 CFD models of the reaction furnace illus- so that a peak in the sulphur concentration Impurity destruction: no significant amounts of ammonia or hydro- At the same time, Duiker’s field reaction (5) and where CO interacts with H2O
trating gas temperature, oxygen depletion, is observed after the combustion zone gen- carbons exist in the RF effluent at chemical observations confirm that, with high- in the reversible water-gas-shift reaction:
sulphur and SO2 formation . erated by the high-intensity burner.
hydrocarbons and ammonia equilibrium, which means that any break- intensity H2S burners, and provided that
24 CO + H2O = CO2 + H2 (9)
At the RF outlet, sulphur concentrations Another important function of the thermal through of these compounds must be due to minimum RF temperature and residence
Sulphur formation in the reaction furnace are indeed found to exceed those at reac- stage of the modified Claus process is to the effect of kinetic limitations in the reaction time requirements are met, very high to form H2 and carbon dioxide (CO2). In SULPHUR
25
ISSUE 375
Chemical pathways are observed that lead tion equilibrium, indicating that the reverse effectively destroy impurities like hydrocar- furnace. The destruction mechanisms are destruction efficiencies are achieved in addition, hydrocarbons dissociate to form
to the partial oxidation of H2S to sulphur in Claus and H2S cracking reactions are, in bons and ammonia (NH3) present in the often considered to be based on the oxidation practically operating units, indicating that hydrogen and carbon (soot), which can be
26 the combustion zone: fact, taking place in the final (and more H2S gas. As reported by Sulphur Experts3, of these compounds directly by oxygen, but other chemical mechanisms must indeed converted by oxygen-containing species
kinetically limited) sections of the furnace. even very small levels of these compounds kinetic experiments performed by the Alberta play a role in the destruction of hydrocar- such as H2O and CO2 or possibly react with MARCH-APRIL 2018
27 H2S + ½O2 → ½S2 + H2O (3) Although the effect is less pronounced in breaking through to the reaction furnace Sulphur Research Ltd (ASRL) have shown that bons and ammonia. sulphur species to form more CS2.
Duiker’s CFD simulations than suggested effluent can cause severe problems in the H2S clearly outcompetes both hydrocarbons Laboratory experiments by ASRL5,9
28 H2S + ¼O2 → ½S2 + ¼H2O + ¼H2 (4)
by its field observations, the sulphur con- downstream process stages: in the case and ammonia for the limited available oxygen, Hydrocarbon conversion under confirm that, under RF conditions, both
in addition to those leading to complete centration in the reaction furnace does of hydrocarbons, rapid deactivation of the which is indeed expected when comparing RF conditions aliphatic and aromatic hydrocarbons
29 oxidation of H2S to SO2 as indicated by seem to approach its equilibrium value catalyst beds by carbon deposition and, in relevant combustion properties such as the In Duiker’s CFD models of the burner/RF lead to significant amounts of CS2 and,
step 1 of the classical two-step mecha- from above as indicated in Fig. 1, and sul- the case of ammonia, plugging of down- flame speeds and auto-ignition temperatures systems, hydrocarbons do not react signifi- at lower temperatures, also to soot for-
30 nism (reaction 1). Significant sulphur gen- phur yields in the thermal stage are thus stream piping and equipment by the forma- of these different compounds4. cantly with the free oxygen in the combus- mation and breakthrough of unconverted
eration is observed in specific parts of the found to exceed the presumed maximum tion and build-up of stable ammonia salts. Duiker’s kinetic simulations based on tion zone of the reaction furnace. However, hydrocarbons. Aromatic hydrocarbons like
31 combustion zone together with hydrogen sulphur yields given by the equilibrium In addition, hydrocarbons can, under cer- detailed chemical reaction schemes (both in even in the absence of free oxygen, hydro- benzene and toluene prove most difficult
(H2) by thermal cracking of H2S according conditions of the Claus reaction (2). More tain conditions, lead to significant soot for- ideal plug-flow configuration as well as with carbons can still react with sulphur spe- to convert at RF conditions due to their Southbank House, Black Prince Road
32 to the reaction: importantly, however, it is observed that mation in the reaction furnace, giving rise full-scale CFD modelling of the burner/RF cies and water to form carbon disulphide chemical stability, so that practical guide- London SE1 7SJ, England
the mixing as induced by the high-intensity to a soot-contaminated sulphur product in system) also show that oxygen reacts most (CS2), carbon monoxide (CO), H2S and H2. lines for dealing with aromatic hydrocar- Tel: +44 (0)20 7793 2567
33 H2S = ½S2 + H2 (5) burners is capable of affecting the course the first sulphur condenser. rapidly and, therefore, predominantly with For example, for methane (CH4): bons include a minimum RF temperature
Fax: +44 (0)20 7793 2577

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5
of 1,050-1,100°C and a residence times hydrocarbons or ammonia can still occur if the COS and CS2 can be converted in the reac- is often focused on return on investment or a short depreciation makes no sense even evaluating an alternative to the most reli- What’s in issue 375
of at least 1.5 seconds3,6. mixing in the reaction furnace is inadequate. tion furnace by hydrolysis reactions: period, the focus should lie with the total cost of ownership (TCO) able equipment available.
Duiker’s CFD simulations with reacting- of the unit. For the TCO evaluation of high-intensity burners as well as
6 Ammonia conversion in RF conditions flow modelling show how the chemical
COS + H2O = CO2 + H2S (11)
Considering that most projects are broken down into distinct the sake of model simplicity it is possible to look at two distinct
In Duiker’s CFD-simulations of the burner/ conversions can easily become mass- CS2 + 2H2O → CO2 + 2H2S (12) phases (e.g. front end engineering design (FEED), engineering effects which are directly related to the mentioned technical ben- ■ COVER FEATURE 1
7 RF systems with detailed chemical-reaction transfer limited, particularly in certain parts and procurement (EP) and construction(C)) and that these phases efits: catalyst selection and the scheduled turn around period.
modelling, it was also found that ammo- of the combustion zone and at the final Laboratory experiments by ASRL also show are often executed by different parties, it should also be consid- Although not all catalyst bed degradation can be ascribed to
8 nia does not react significantly with free sections of the reaction furnace. Indeed, significant conversion of CS2 with SO2 to ered when and by whom this evaluation should be done. Although poor combustion, RF performance determines the composition of Middle East
oxygen in the combustion zone of the reac- when mixing is poor, raising RF tempera- form CO, COS, and sulphur, as well as most operating companies internally evaluate the capital expense the process gas stream and the quantity of impurities that the Sulphur
9 tion furnace (as a consequence of the tures or increasing residence times beyond other reactions paths involving hydrogen (capex) and operational expense (opex) related to FEED proposals, catalyst beds are exposed to.
rapid reaction of the oxygen with H2S and minimum levels becomes less effective, and CO2. the EP(C) proposals often are evaluated based on only the capex It is clear however that the complete destruction of aromatics Conference,
10 sulphur species). ASRL7,8 has also deter- and these actions are no substitute for Duiker’s field data show that par- or total installed cost (TIC). and limiting the CS2 exposure of the catalyst beds leads to dif- Abu Dhabi
mined experimentally that ammonia disso- intense, well-controlled mixing patterns in ticularly the CS2 concentration in the RF Furthermore, as EP(C) contracts are often signed on a lump ferent selection criteria for the type of catalyst to be utilised. The
11 ciation to nitrogen (N2) and hydrogen (H2) burner/RF systems. effluent can deviate significantly from the sum basis, generally in this stage of the project, no involved party effect on the TCO is very significant as the prevention of having
is strongly inhibited by both H2O and H2S, In addition, Duiker’s CFD models show equilibrium state of reaction (12). In reac- engages in any further evaluation. Thus, for most SRU projects, to resort to using high grade catalysts has a recurring effect with
12 so that this mechanism is also unlikely to how the intense mixing induced by the tion furnaces handling hydrocarbons, CS2 only one evaluation takes place and this is at the front end of every catalyst change. ■ COVER FEATURE 2
contribute significantly to NH3 destruction burner brings hydrocarbons and ammo- is nearly always found in the RF effluents the project. Furthermore, it has been found that a cleaner process gas
in the burner-RF system. nia impurities in close contact with sul- even at high furnace temperatures, indi- What is thus often underrepresented in this process are the extends the effective catalyst life. This effect is also recurring
13 North Africa’s
However, it is also found by ASRL7,8 phur species and SO2 already generated cating that adequate mixing is important non-direct, long term costs and benefits associated with the differ- since often a larger turnaround is scheduled around the replace-
14 that NH3 reacts readily with SO2 even at by the (partial) oxidation of H2S. In fact, right up to the final sections of the reac- ent equipment available to the operators. Summed up by George ment of the catalyst. phosphate industry
relatively low RF temperatures according to to accommodate the full oxidation of the tion furnace to reduce mass-transfer limi- Orwell in: “All animals are equal, but some animals are more This extension is not only beneficial through reducing the
the reaction: hydrocarbons and ammonia impurities in tations. As already stated, mass-transfer equal than others.”; an approved vendor list provides only a rudi- expense on catalyst material, the extended cycle also reduces
15 the H2S feed, more air or oxygen is nor- processes in the reaction furnace can eas- mentary safeguard against poor performing or untested vendors the maintenance expense.
NH3 + ½SO2 → ½N2 + ½H2S + H2O (10)
mally introduced via the burner. Since this ily become rate-limiting, so that enhanced but no basis for an evaluation between their offerings. Considering Taking these different effects into account, it makes sense ■ COVER FEATURE 3
16 where again H2S is subject to dissociation oxygen is found to react predominantly CS2 conversions are indeed expected when an elevator, an escalator and stairs, it is evident that although to evaluate investment decisions not only from a FEED evalu-
via reaction (5) to produce both H2 and sul- with H2S rather than with the impurities strong and efficient mixing patterns are they all perform the same core function, the costs associated ation perspective, but from a detailed engineering perspective
17 phur and where H2S can react with SO2 to themselves, even higher concentrations created throughout the reaction furnace. with them are not. as well.
SRU combustion
produce sulphur according to the Claus reac- of SO2 and sulphur species are created in Duiker’s CFD simulations clearly reveal For operating companies it is thus in their own best interest challenges
18 tion (2). Together with the direct oxidation of the combustion zone when impurities are these mixing patterns as created by the to weigh options and proposals internally and by stakeholders
H2S by free oxygen in the combustion zone handled, and these compounds are then high-intensity H2S burner, and this may, in whom are familiar with the scope. For an SRU, in addition to the
19 as given by reaction (1), the overall effect of found to interact with the hydrocarbon and itself, explain the typically lower CS2 con- capex and opex evaluation based on figures presented by outside
reaction (10) in the reaction furnace is the NH3 impurities by intense mixing. centrations found in the RF effluents. CS2 sources, this evaluation can include for instance: labour cost due ■ COVER FEATURE 4
20 indirect oxidation of ammonia by oxygen to Such chemical interactions, facilitated conversion may also be facilitated by flow to maintenance and repair, catalyst lifetime differentials, required
nitrogen (N2) and water (H2O). by favourable and well-controlled flow patterns that enhance the chemical inter- shutdown schedule, consumables consumption, etc. Considering
Sulphuric acid
21 Duiker’s kinetic calculations using patterns, could contribute significantly actions of CS2 with species like SO2 (as these additional parameters it is clear that some SRUs are defi-
detailed chemical reaction schemes to the high levels of impurity destruction explained earlier), but this effect on CS2 nitely more equal than others. plant simulation
22 indeed show a significant enhancing effect observed in the field with the high-intensity conversion in the reaction furnace is cur-
of SO2, and to a lesser extent of CO2, on H2S burners. rently unclear. High-intensity burners
23 ammonia conversion at RF conditions, As discussed earlier, high-intensity burners are differentiated from
although the level of conversion in these Sulphur by-products Total cost of ownership non high-intensity burners not simply by the fact that they perform
calculations is underestimated when con- the same function quicker, better or more efficiently, they per-
24
sidering the very high ammonia destruction Carbonyl sulphide (COS) and carbon disul- Driven by international regulators demand- form the function in a completely different manner. The resulting

25 levels that are observed in the field with phide (CS2) are undesired sulphur by-prod- ing the minimisation of sulphur emissions, benefits: higher sulphur production in the reaction furnace, bet- SULPHUR

ISSUE 375
the high-intensity H2S burners. The proper ucts that, unless effectively converted in the installing and operating a sulphur recovery ter destruction of impurities and lower CS2 concentrations in the
destruction of NH3 is generally considered first catalytic stage of the Claus process, unit (SRU) is an unavoidable investment reaction furnace effluent, are well established through anecdotal
26 to require reaction furnace temperatures reduce the sulphur recovery of the modified for many operating companies. Although evidence. So although the technical benefits of installing a high
of at least 1,250°C and a residence times Claus process. the design, detailed engineering, installing intensity burner in the main reaction furnace of an SRU are gener- MARCH-APRIL 2018
27 of 1 second. Interestingly, Duiker’s full- While COS formation in the reaction furnace and operating of these SRUs are consid- ally accepted and acknowledged, how this translates to the bot-
scale CFD simulations under these condi- is associated primarily with the reactions of ered a well-developed, mature industry, tom line is much less clear.
28 tions tend to show higher levels ammonia H2S and sulphur species with carbon oxides the investment evaluations are often still Considering the function and the expected service life of an
destruction than its kinetic calculations (CO2 and CO), CS2 is formed in the reaction performed within a framework which is not SRU, it becomes evident that one factor governs any type of TCO
29 based on ideal plug-flow configurations, furnace as a direct result of hydrocarbon designed for this purpose. Despite the fact analysis performed; reliability. Unscheduled downtime will govern
pointing at the role of the flow and mixing destruction. that the SRU generates large amounts of any TCO analysis performed due to loss of production and repair
30 patterns in the burner/RF system. Again, thermodynamic calculations energy and produces elemental sulphur costs involved. Consider the repair of a tube breach in a waste heat
show that, at least for CS2, a very low which is a saleable product, at the bot- boiler. Even in small facilities this activity can take a week simply
31 Effect of high-intensity mixing concentration exists in the RF effluent at tom line, the SRU does not contribute to due to the fact that a controlled cool down is required before the
As stated, sufficient temperature and chemical equilibrium, indicating that the the margin but is a net cost centre. Thus, repair can take place. After performing the repair the reaction fur- Southbank House, Black Prince Road
32 residence time in the reaction furnace are conversion of this species is kinetically instead of performing a traditional evalua- nace needs to be slowly heated up to prevent refractory damage. London SE1 7SJ, England
essential requirements for proper impurity limited at RF conditions. Besides several tion designed for a profit centre, which is From a financial perspective, reliability for any process critical Tel: +44 (0)20 7793 2567
33 destruction, but significant breakthrough of other reactions involving various species, often focused on return on investment or a part of the SRU is thus so crucial that from a TCO perspective it
Fax: +44 (0)20 7793 2577

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5 Fig. 10: Typical Siirtec Nigi acid gas burner assembly Fig. 11: Temperature profile of new Siirtec Nigi burner Fig. 12: Optimised design of reaction furnace Fig. 13: Pre-formed bricks around manhole What’s in issue 375
ceramic blanket
6 150
° to
p

°
■ COVER FEATURE 1

150
antacid mortar
7
8 Middle East
Sulphur

210°
9
ceramic paper, type for 210°
Conference,
10 Abu Dhabi
photo: Siirtec Nigi

photo: Siirtec Nigi

1, .0
1, .0
1, .0
1, .0
0
mortar

0.
0
0
0
0
0

1, .0
0
0
0
0
0.
0.
0.
0.
0.

04
13
22
31
40
0
11

50
59
68
77
86
95
insulating bricks hot face bricks
temperature, °c
12 Source: Siirtec Nigi
Source: Siirtec Nigi ■ COVER FEATURE 2

13 North Africa’s
Revamping the SRU thermal items of SrU equipment, Siirtec Nigi also in the design of its latest acid gas burn- l the pressure drop on the acid gas side (up to approx. 6 m in diameter). Special Siirtec Nigi has implemented medium-
14 section acts as an integrator in the early stages ers. the new burner design benefits from has been kept below 400 mm w.c., attention was required to evaluate the ther- to-high oxygen enrichment levels in several phosphate industry
of projects, using its extensive experience sub stoichiometric combustion of the which is beneficial for the total pres- mal stresses across the junction where refineries, including: Api Falconara refinery,
over the last ten years Siirtec Nigi has and knowhow to understand and intercon- acid gas. Because of the relatively low sure drop of the SrU, as advised for the thermal furnace connects to the down- porto Marghera refinery and taranto refin-
15 been requested by many refineries and nect all critical aspects of these systems air/acid gas volumetric ratio, the high plant revamps. stream waste heat boiler, to evaluate fur- ery in italy and Barrancabermeja refinery
gas processors to study the revamp of to deliver successful outcomes. velocity wide-angle injection of acid gas nace cooling for conditions deviating from in colombia. For these references, due to ■ COVER FEATURE 3
16 existing claus plants to treat new gas into the air promotes a swirling motion Fig. 11 shows a cFD temperature profile of normal operation, as well as to address the maximum temperature limits of the high
compositions and to meet new capacity Improved acid gas burner design of the reactants achieving good mixing the new Siirtec Nigi burner. Acid gas burners design challenges related to the correct alumina refractory, oxygen cannot simply be
17 requirements, while minimising the invest- Some of the key challenges for the and a good temperature profile. this is of this design have been supplied and tested calculation and installation of the refrac- added to the acid gas burner, highly special-
SRU combustion
ment costs and reducing as practically as improved acid gas burner design were: particularly important for oxygen enriched since 2010. references include SrUs oper- tory linings. ised staged oxygen burning is required. challenges
18 possible the shutdown period for the site l to design the burner for acid gas com- air operation. ated with combustion air only e.g. for Vis- the improvements to the hydraulics and An uncommon but key benefit of Siirtec
activities. bustion at high temperature i.e. 1,550- colube plant, italy, (2010), cpLc refinery, refractory of the reaction furnace design Nigi reaction furnaces is the flexibilty
19 to meet these demands Siirtec Nigi 1,600°c, avoiding damage to the Key features of the improved burner design india (2012), Afipski refinery, russia (2015) are summarised below: to design them with oxygen enrichment
has developed a new, high performance burner lance caused by overheating; include: and pavlodar refinery, Kazakhstan (2016), l the hydraulic performance of the reac- capability already built-in should the cli- ■ COVER FEATURE 4
20 thermal section (burner + furnace), which to achieve this, the burner should be l the combustion air box has been re- and SrUs designed for oxygen-enriched air tion furnace has been optimised by ent decide to implement it at a later date.
can be considered for the revamp of exist- designed to maximise the cooling effect designed internally to assure uniform operation at iplom refinery, italy (2010) and installation of high efficiency burners this design was provided for taranto refin-
Sulphuric acid
21 ing claus plants to boost the overall sul- of the acid gas and air streams and to distribution of the air stream all around Sines refinery, portugal (2010). able to generate a relatively short flame ery, italy (2007), Sannazzaro refinery,
phur recovery efficiency10. expose the burner tip to combustion the acid gas lance; pressure drop on the burner performance has been with a large volume and distribute the italy (2007) and Sines refinery, portugal plant simulation
22 it is well known that the capacity of an products at temperatures lower than air side has been kept at 250-300 mm satisfactory for both high temperature combustion product gases across the (2010); oxygen enriched capability was
existing claus plant can be increased by the expected adiabatic temperature. w.c. as typical of the traditional Siirtec combustion and for destruction of contam- whole section of the furnace, thereby included in the design from the beginning
23 adding oxygen to the combustion process. l to obtain a short flame length with Nigi burner and as result no increase of inants present in acid gas streams. the avoiding channelling of hot gases and allowing these units to be operated at
the level of air enrichment is in the range no refractory impingement, maximis- the noise level has been noted over the good results and feedback from clients maximising the residence time increased capacities by basically switch-
30-40 vol-% oxygen when refinery acid gas ing the reaction furnace volume avail- typical 75-80 dBA range. has been instrumental in the continuing l the refractory lining of reaction furnace ing to a new oxygen enrichment acid gas
24
is treated. higher oxygen enrichment, up able for the post flame reactions; the l the acid gas lance has been provided improvement and optimisation of Siirtec has been improved by applying the fol- burner, without having to re-consider all the

25 to 100% pure oxygen is applied to SrUs flame front should also be sufficiently with a proprietary tip design which Nigi burners. recently new burners have lowing design criteria: critical integration aspects that this switch- SULPHUR

ISSUE 375
with dilute acid gas feed streams.such as wide so that no channelling of combus- promotes the swirling motion of com- been supplied to cpcL refinery, india 2017 m hot face refractory layer has been ing operation would normally require, and
those typically found in natural gas produc- tion products takes place in the reac- bustion products; this performance and taranto eNi refinery, italy (2018). in assembled with properly tapered significantly reducing down-time.
26 tion fields. tion furnace. has been confirmed by numerous cFD eNi refinery the new burners are specifi- high alumina bricks to reduce the
Siirtec Nigi has many years of experi- l to avoid vibrations and noise, as typi- analyses performed on the coupled cally designed for oxygen enriched air to risk of sagging; Reaction furnace internals to MARCH-APRIL 2018
27 ence in the design, fabrication and supply cally noted in the operation of some burner-furnace system. the cFD analy- increase the SrU capacity by 35%. m a radial expansion joint filled by
of acid gas burners for SrUs, especially for high intensity burners, to assure sis is performed using a suitable kinetic ceramic blanket has been provided
boost performance
28 operation with oxygen enriched air. Burn- smooth burner and plant operation model representing the typical reac- Improved reaction furnace design at the top of the furnace to accom- the burner plays the most important role in
ers have been supplied and installed to l to design the burner for low pressure tants pool present in the thermal stage Siirtec Nigi has also devoted much effort in modate the differential thermal the achievement of proper combustion in
29 over 120 claus plants worldwide (Fig. 10). drop on both the acid gas side and the of a claus unit and is supported by the recent years to improve the reliability of the expansion between the refractory the SrU reaction furnace but the tempera-
in the past decade Siirtec Nigi has combustion air side; this requirement back-up of a consistent and updated reaction furnace, with particular focus on and the furnace casing, thus avoid- ture in the combustion zone/front end of
30 invested particular effort to the improve- is very important in case of claus plant plant data collection and by collabora- the hydraulics and refractory stability. Both ing plastic deformation of the bricks the furnace can be further enhanced by the
ment of its own acid gas burners and reac- revamps, since the existing air com- tion with respectable universities. aspects are important for high tempera- at high temperature (Fig. 12); preheating of the process gases and the
31 tion furnace designs, they are treated as a pressors should be retained to mini- l the flame core temperature has been tures of oxygen enriched air combustion m pre-fired blocks are installed around combustion air, the co-firing of fuel gas,
single coupled system that must be prop- mise investment cost. found to be systematically higher than and for big furnaces with large diameters. the openings such as manholes, and the redirection of some of the acid gas Southbank House, Black Prince Road
32 erly handled and designed. the adiabatic combustion temperature the oxygen-enriched reaction furnaces nozzles etc. to improve the stabil- flow towards the back of the reaction fur- London SE1 7SJ, England
in addition to being an SrU licensor, Siirtec Nigi have successfully imple- which is beneficial for the kinetics of supplied by Siirtec Nigi for the Shah gas ity of the hot face refractory layer in nace (rF) to achieve a more stoichiometric Tel: +44 (0)20 7793 2567
33 epc contractor and supplier of critical mented all of the above requirements contaminant destruction reactions. project are among the largest in the world those areas (Fig. 13). combustion ratio.
Fax: +44 (0)20 7793 2577

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This is more than a

▼
2 SRU theRmal Section

Sulphur Recovery Unit

■ CONTENTS
4
5 Fig. 14: Failure of conventional cylindrical and matrix box checker walls existing structures failed frequently and What’s in issue 375
often didn’t survive an entire campaign
intact. the result was the development of
6 the blasch hexWall checker wall. the hex-

7
Wall blocks which range in depth from 9
to 18 inches (23 to 46 cm) are designed
“It’s the culmination of more than ■ COVER FEATURE 1

8
to be stacked dry and are mechanically
engaged through a series of tabs and
60 years of sulphur leadership. Middle East
slots, so the wall is quite stable, even It represents knowledge from Sulphur
photos: blAsch

9 when several metres in diameter. No mor-

tar is used between the blocks, allowing technical experts around the world, Conference,
10 Abu Dhabi
and opportunities to learn from
the interlocking assembly to accommo-
date the thermally driven expansion and
11
Fig. 15: Blasch VectorWall
contraction that comes with RF operation.
the walls may either be erected into a slot them. And it’s my contribution in
12 in the existing lining, or installed against
the hot face brick with a course of brick on
safely delivering clean fuels to my ■ COVER FEATURE 2

13 either side to lock it in.

over the next several years, as the stabil-
hometown.” North Africa’s
ity and durability of the hexWalls was proven, - Oscar D., WorleyParsons phosphate industry
14 attention turned towards additional benefits Mechanical Engineer, USA
that could be provided by refinement of the
15
photos: blAsch

structure. In the context of the “3 ts” of

combustion (time, temperature and turbu- ■ COVER FEATURE 3
16 lence), the benefits of higher front zone tem-
peratures had already been demonstrated,
17 thus facilitating the important destruction of
SRU combustion
In terms of turbulence and mixing, even temperatures in the front zone that are hydrocarbons, ammonia and btX. the focus challenges
18 the best burners can’t maintain complete necessary for ammonia destruction, caus- thus became on how to improve mixing in
mixing across the entire length of the reac- ing deposits of ammonium bisulphate/sul- the reaction furnace (turbulence) and thereby
19 tion furnace and internal structures such phate in the downstream equipment. this also minimise any channelling /stratification
as checker walls or choke rings are often is another factor requiring shutdown of the of the gases and thus ensure sufficient resi- ■ COVER FEATURE 4
20 deployed to promote mixing and provide sRU at significant economic cost. dence time in the furnace.
other benefits11.
Choke rings
A vectoring hood was developed that
Sulphuric acid
21 would fit into the outlet ends of the exist-
Checker wall systems A choke ring is used to reflect back some ing blocks in the hexWall design, and could plant simulation
22 the conventional roles of a checker wall in of the flow and create a degree of back mix- be oriented in such a way as to redirect, or
the reaction furnace are to help increase ing in the front zone of the furnace. how- ‘vector’, the down-stream flow allowing the
23 front zone temperatures, protect the tube ever, a large portion of the flow jets through assembly to contribute to the creation of
sheet from radiant heat and improve mix- the center of the ring and jeopardises the the overall desired flow. the vortex was ini-
ing to some degree. achievement of the minimum residence tially selected because it was felt that this
24
conventional checker walls in sRUs time requirements in the furnace. Many configuration made the best use of the fur-

25 either have a cylindrical shape to help plants also use a traditional checker wall nace volume and created a flow pattern that SULPHUR

ISSUE 375
resist high stress due to the geometry, or a in front of the tube sheet to protect it from yielded a long path length with a very tight
matrix box shaped brick system jointed with impingement by this strong jet. residence time distribution. the configura-
26 mortar that can often fail due to thermal tion was designed to provide the flow pattern
shock cycling, mortar failure and vibration. Blasch HexWall and VectorWall of a plug flow reactor and make the most MARCH-APRIL 2018
27 In addition to that, running the unit above blasch hexWalls and VectorWalls have effective use of the existing furnace volume.
its design capacity causes damage to the been successfully deployed in both refinery this variation of the hexWall checker wall
28 conventional checker wall as it cannot sus- and gas plant sRUs ranging in size from was christened the VectorWall (Fig. 15).
tain high vibration at over-design flow rates. under 100 t/d to over 2,000 t/d. Working It had been observed at VectorWall
29 Fig. 14 shows damage caused to both jointly with process licensors, refractory retrofits that the choke ring configuration

30
checker wall designs. the high failure rate
of checker walls leads to high repair costs
suppliers and operating companies and
with the help of sophisticated cFD analy-
seemed to allow a portion of the process
flow out of the furnace well before any
Deep local knowledge.
from frequent and prolonged shutdowns sis, blasch has continued to improve the published minimum residence time num- Global expertise.
31 and this cost exponentially increases if it design of these critical RF internals. bers are met. It was believed that the
leads to having to cut upstream production. blasch’s original objectives for a dramatic improvements seen in the field Anywhere in the world. Southbank House, Black Prince Road
32 Damage to conventional checker walls checker wall were to provide a structure with the VectorWall were due to the tighter sulphurtechnology@worleyparsons.com London SE1 7SJ, England
due to loss of structural integrity can also that was more mechanically stable based residence time distribution and the ten- Tel: +44 (0)20 7793 2567
33 lead to not being able to achieve the high on several customer complaints that their dency of the wall to keep the amount of
Fax: +44 (0)20 7793 2577

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1

▼
2 SRU theRmal Section SRU theRmal Section

3
■ CONTENTS
4
5 Fig. 16: Reaction furnace temperature before and after Fig. 17: Gas processing rate before and after observations from the field by modelling the of the flow did not meet NH3 destruction visibility through the pyrometer lens. But What’s in issue 375
VectorWall revamp VectorWall revamp performance of the two reactor configura- residence time requirements with the what should plant operators do when mul-
tions with respect to velocity distribution, choke ring configuration per the CFD anal- tiple instruments have been installed which
6 before revamp after revamp before revamp after revamp flame shapes, residence times (especially ysis. (Fig. 20). With the VectorWall, all of are indicating different temperature read-
1,500 2,500
7 1,400 2,250
related to ammonia destruction require- the Zone 1 gas flow meets retention time ings? A high temperature indication could be ■ COVER FEATURE 1

foul sour gas processing rate, m3/hr

ments) and other parameters of interest. requirements for NH3 destruction. construed that the temperature is approach-
1,300
2,000 Several key insights were gained from The low residence times in the choke ring ing refractory limitations, which could lead to
flue gas temperature, °c

8
1,200
1,100 1,750 the CFD analysis: configuration are consistent with field perfor- failure of the thermal reaction furnace and/ Middle East
1,000 1,100 Improved flame characteristics and mance, as the choke ring configuration was or waste heat boiler protection system. A low Sulphur
9 900 1,500 reduced vibrations found to have ammonium bisulphate/sul- temperature indication could be construed to
800 1,250 With the choke ring, pressure waves phate in downstream equipment, providing be incomplete conversion of contaminants Conference,
700
10 600
1,000
750
reflecting off the choke ring result in a evidence of insufficient ammonia destruction. such as heavy hydrocarbons, BTEX or ammo- Abu Dhabi
500 zone (i) flue gas
flame shape within the burner can that nia which may cause plugging and fouling in
500
11 400
300
zone (ii) flue gas
250
likely caused the unstable vibrations during Improved overall mixing and furnace downstream reactors and condensers. Both
operation. As can be seen in Fig. 18, the operation underestimation and overestimation of the
200 0
12 flame spreads to the ID of the burner can’s With the VectorWall, backpressure was temperature indication can pose particular ■ COVER FEATURE 2
Source: Blasch Source: Blasch refractory and is not closed. Instead it is reduced and a proper flame jet was formed dangers and plant operators will respond in
open, as shown by the centrally located from the burner throat with the flame extend- contradiction to the need of the actual situa-
13 North Africa’s
streamlines released from the acid gas ing out of the burner can (Fig. 19), resulting tion in the furnace. In addition, start-up and
14
Fig. 18: Mean flame shape with choke ring configuration Fig. 19: Velocity magnitude comparison inlet passing relatively undisturbed through in a higher intensity flame and better mixing. drying-out operations pose other challenges phosphate industry
the core of the flame. This is unusual and The absence of a centreline jet down- as these operating conditions can lie outside
choke ring indicative of poor combustion quality, pos- stream of the separator in Zone 2 results in the measurement range of the temperature
15 sible refractory damage, and high pres- a very tight residence time distribution. The instruments. Typically, dedicated start-up
sure variations – likely manifesting as high low temperature region resulting from the thermocouples or other means of tempera- ■ COVER FEATURE 3
16 in-service noise/vibrations. One of the Zone 2 acid gas inlet just downstream of the ture measurement may have to be used.
important findings from the analysis was VectorWall is smaller than that in the choke The question of which temperature meas-
17 VectorWall
that the VectorWall caused a significant ring configuration due to improved mixing in urement can be trusted is often posed to the
SRU combustion
reduction in the interactions between the Zone 2 with the VectorWall configuration. licensors/engineering firms who can calculate challenges
18 flow local to the burner and the separator. an expected reaction furnace temperature
Reduced pressure drop using simulation software with validated cal-
19 90 392 694 996 1298 1600 0 20 40 60 80 100 Improved ammonia destruction Pressure drop through the VectorWall con- culation methods. These methods will include
With the choke ring, a significant centre- figuration is ~900 Pa lower than the choke parameters such as composition of the gases ■ COVER FEATURE 4
20 temperature,°c velocity magnitude, m/s
line jet formed through the separator as ring configuration. The significant differ- entering the reactor and heat losses. Plant
Source: Blasch Source: Blasch shown by the “bullet” shaped protrusion ence in pressure drop is likely caused by operators most often do not have the benefit
Sulphuric acid
21 in the choke ring configuration versus the the spread of the flame in the burner can, of such simulation tools or heat models.
VectorWall configuration (Fig. 19), result- which must then be turned back to pass The Temp-Protect tool is a Jacobs plant simulation
22 unreacted material from getting out of the Fig. 16 compares the furnace tem- CFD modelling of choke ring and vector ing in a spread in the residence time dis- through the choke ring. development that calculates the tem-
furnace to a minimum. Subsequent CFD peratures before and after a revamp at wall configurations tribution and some of the flow passing perature of the reaction furnace based
23 modelling confirmed this hypothesis. a refinery that was experiencing serious through the reaction furnace without ade- Further potential improvements on a heat balance correlation. The inputs
Another advantage of the VectorWall, problems with their checker wall and Detailed computational fluid dynamics quate residence times for completion of Flow tracing methods indicate that blocking for this calculation are measured signals
which is under constant refinement based with ammonia destruction and decided (CFD) analyses were performed with Porter the desired reactions. One of the strong- the manway of the VectorWall should further which are already available in the DCS
24
on customer feedback, is that the size to install a Blasch VectorWall. It can be McGuffie, Inc. recently to characterise and est manifestations of this is that 22.5% improve mixing and increase residence time and analysis of the acid gas composition

25 and angle of the vector hoods can be seen that after the revamp, the Zone I compare the performance of a SRU reaction beyond what has already been observed. is not required. The benefit of this tool is SULPHUR

ISSUE 375
customised to provide the degree of mix- temperature increased by about 100°C, furnace at a refinery in Asia where the choke Fig. 20: Cumulative distribution a continuous calculation and prediction of

26
ing, shielding of the tube sheet, and to thus solving the problem with ammo- ring in the furnace had been replaced with functions of residence time Temperature monitoring in the the expected gas temperature. The main
limit the heat loss from the front zone of nia destruction. The presence of the a VectorWall. Prior to the revamp, when the at T >1,250°C characteristics of this tool are:
the reaction furnace. There are now well Vector hoods in the blocks also helped reactor was equipped with a choke ring, the
reaction furnace l independent means of temperature MARCH-APRIL 2018
27 over a hundred HexWalls and VectorWalls with reflecting more radiant heat back SRU was limited in capacity by vibrations Vertical dashed line indicates cutoff One of the challenges in the reaction furnace indication of the reaction furnace;
residence time for contaminant destruction
installed worldwide. into zone 1. The refinery was also able and insufficient ammonia (NH3) destruction. of a sulphur recovery unit is to measure the l fast and precise reference point for the
28 Based on a deepened understanding to increase the sour water stripper gas The latter, despite the acid gas being split 100 correct temperature of the process gas12. In temperature readings of the reaction
of the various benefits of VectorWalls and (SWSG) by about 30% as seen in Fig. 17 between the front zone and the zone behind 80 choke ring the past, thermocouples were prone to corro- furnace;
29 client feedback, it is felt that gas plant and in addition no more furnace vibra- the choke ring to achieve more stoichiomet-
cDF, %
60 sion and/or measured the refractory temper- l the tool can be used for all operating
SRUs, which are often very large with the tions were observed as was the case ric combustion and higher temperatures for ature if not properly positioned. Pyrometers conditions: start-up, fuel gas firing, oxy-
40
30 attendant concerns of stability of conven- prior to the VectorWall revamp. better ammonia destruction. VectorWall show sensitivity to fouling and drift over time gen enrichment etc.;
20
tional checker walls and which also face The VectorWall has also been deployed After replacing the choke ring with a and can also indicate the refractory temper- l additional check on flow instruments of
31 the challenge of achieving adequate tem- in sulphuric acid plants to effect a more VectorWall, the SRU could process acid gas 0 ature in case of misalignment. The perfor- acid gas and fuel gas;
0 0.5 1 1.5 2
peratures for BTX destruction, can stand efficient and compact furnace design and at higher capacity, achieved much better mance of these instruments has improved l tailored to each individual plant: geom- Southbank House, Black Prince Road
32 to benefit the most from this advancement also address issues relative to NOx which NH3 destruction and vibrations were elimi- residence time at t >1,250°c, sec over time via the introduction of purged etry and design of the reaction furnace is London SE1 7SJ, England
in sulphur recovery unit reaction furnace is always of concern in sulphuric acid nated. The CFD analysis helped provide a Source: Blasch ceramic sleeves protecting the thermocouple included in the calculation as each design Tel: +44 (0)20 7793 2567
33 internals. regeneration (SAR) plants. theoretical understanding of this and other and better purge designs to maintain clear and installation has its own heat loss;
Fax: +44 (0)20 7793 2577

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1

▼
2 SRU theRmal Section

3
■ CONTENTS
4
5 Fig. 21: Case 1: reaction furnace temperature measurements This check provides the operators with What’s in issue 375
more security and reduces time spent on
maintenance by having to check and recali-
6 1,500
1,450 brate both instruments.

7
1,400 These cases illustrate the benefit of ■ COVER FEATURE 1
1,350 having additional temperature monitoring
temperature, °c

1,300 tools in place. There have been numerous

8 1,250 incidents in the industry where overheat- Middle East
1,200 ing of refractory with subsequent failure Sulphur
9 1,150 of the furnace shell took place as plant
1,100 operators relied on the temperature instru- Conference,
1,050
10 1,000
ments which indicated temperatures that Abu Dhabi
were too low. Addition of more fuel gas can
26.02.16 27.02.16 28.02.16 29.02.16 01.03.16
11 iR front iR back temp-Protect back
result in temperatures well over 1,500°C.
These incidents could potentially have
12 Source: Jacobs been avoided if operators were warned ■ COVER FEATURE 2
via an independent temperature indica-
tion which would have led to a check of
13 Fig. 22: Case2: reaction furnace temperature measurements North Africa’s
the instruments. As the Temp-Protect tool
14 uses the flow signals of the acid gas and phosphate industry
1,380 fuel gas streams, it can also serve as a
1,370 check for the flow instruments belonging
15 to these streams. n
1,360
temperature, °c

■ COVER FEATURE 3
16 1,350
1,340 References
17 1,330 1. Lems S. and Hoffland S. (Duiker Combustion SRU combustion
1,320 Engineers): “Effects of mixing on main reaction
challenges
18 1,310
furnace chemistry and total cost of ownership”,
Sulphur 2014 Conference, Paris (Nov 2014).
1,300 2. Borsboom H. and Clark P.D., ASRL Quarterly
19 20.04.17 22.04.17 24.04.17 26.04.17 Bulletin No. 120 Vol. XXXVIII No. 4, pp. 1-62
mcc pyrometer, °c mcc thermocouple, °c temp-Protect back (Jan-Mar 2002). ■ COVER FEATURE 4
20 Source: Jacobs 3. Paskall H.G. and Sames J.A.: “Sulphur Recov-
ery”, Sulphur Experts Western Research,
12th ed., (2009). Sulphuric acid
21
l changing process conditions included: reading at the back-end of the reaction fur-
4. Clark P.D., Dowling N.I., and Huang M., ASRL
Quarterly Bulletin, Vol. XXYIV, No. 4, pp. 1-50 plant simulation
22 effect of composition, flow, preheat, etc. nace. Changes in flow and composition are (Jan-Mar 1998).
The Temp-Protect output in DCS allows captured by this tool as illustrated by the 5. Clark P.D., Dowling N.I., and Huang M., ASRL

23 operators to check the validity of their reac- rapid response. Overall the Temp-Protect Quarterly Bulletin, Vol. XXXIII, No. 3, pp. 1-18
(Oct-Dec 1996).
tion furnace temperature instruments via tool correlates well with the expected tem-
6. de Wolf-Rikkers, J., Jacobs Comprimo Sulfur
an independent value. Two case studies perature of the reaction furnace.
24 Solutions, Gas Treating & Sulphur Technol-
are presented to illustrate the functionality ogy Seminar 2011 (Nov 20-22, 2011).
of the Temp-Protect tool. Case 2 SULPHUR
25 7. Clark P.D., Dowling N.I., and Huang M., ASRL

ISSUE 375
In this refinery SRU thermal reaction fur- Quarterly Bulletin, Vol. XXXIV No. 4, pp. 1-50
Case 1 nace, both a thermocouple and pyrometer (Jan-Mar 1998).
26 Temp-Protect was installed in a refin- were installed (Fig. 22). The difference 8. Clark P.D., Dowling N.I., and Huang M.,
ery SRU with two pyrometers (Fig. 21). A in readings between the two instruments ASRL Quarterly Bulletin, Vol. XXXVI No. 1, MARCH-APRIL 2018
27 100°C difference was measured between was only 40°C which shows proper cali-
pp. 67-93 (Apr-Jun 1999).
9. Clark P.D., Dowling N.I., and Huang M., ASRL
the two pyrometers which could not be bration of both instruments. The Temp- Quarterly Bulletin, Vol. XLVII No. 4, pp. 30-44
28 explained by location only or a difference in Protect estimation of the temperature (Jan-Mar 2011).
heat loss alone. Recalibration of the front corresponds well with either one of the 10. Perego G. (Siirtec Nigi): “How to improve the
29 pyrometer was advised in this instance. Of temperature instruments. Although in this SRU thermal section”, written for Sulphur
particular interest in this scenario was to scenario there was no need for verification (Feb 2018).
30 know whether the temperature was high of either instrument as both were properly 11. Parekh U., (Blasch Precision Ceramics):
“Development of robust SRU reaction furnace
enough for complete ammonia destruction. functioning, this example does illustrate internals to improve mixing and overall perfor-
31 The green line represents the calculated the potential of this tool. Whenever these mance”, written for Sulphur (Feb 2018).
values of the Temp-Protect tool which are readings are prone to diverge, the Temp- 12. Roelofs T. and van Son M. (Jacobs) : “Moni- Southbank House, Black Prince Road
32 in line with the back-end pyrometer. The Protect reading can be used as an addi- toring of the temperature in the reaction London SE1 7SJ, England
total heat loss was taken into account tional check-point to quickly assess which furnace – Temp-Protect”, written for Sulphur Tel: +44 (0)20 7793 2567
33 which corresponds to the temperature instrument shows a deviating value. (Feb 2018).
Fax: +44 (0)20 7793 2577

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▼
2
3 Advertisers’ index
■ CONTENTS
4
5
Editor: RICHARD HANDS
richard.hands@bcinsight.com
Advertiser Page Website What’s in issue 375
Technical Editor: LISA CONNOCK Aumund 11 Aumund.de
6 lisa.connock@bcinsight.com

7
Contributor: OLIveR HAtfIeLD AXENS 33 axens.net ■ COVER FEATURE 1
oliver.hatfield@integer-research.com

Blasch Precision Ceramics 13 blaschceramics.com

Middle East
Publishing Director: tINA fIRMAN
8 tina.firman@bcinsight.com

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10 Claims for non receipt of issues
must be made within 3 months of
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Fluor Corporation IFC fluor.com
the issue publication date.
11
Sales/Marketing/Subscriptions: Hugo Petersen GmbH 9 hugo-petersen.de
MARLeNe vAz
12 tel: +44 (0)20 7793 2569 ■ COVER FEATURE 2
fax: +44 (0)20 7793 2577 Jacobs/Chemetics 27 jacobs.com/chemetics
13 marlene.vaz@bcinsight.com
Cheques payable to BCInsight Ltd Jacobs Comprimo Sulfur Solutions 17 Jacobs.com/comprimo-sulfur-solutions North Africa’s
14 Advertising enquiries: phosphate industry
tINA fIRMAN OHL Gutermuth Industrial Valves GmbH 21 OHL-gutermuth.de/en
tina.firman@bcinsight.com
15 tel: +44 (0)20 7793 2567
Prosernat 15 prosernat.com/en
Agents:
■ COVER FEATURE 3
16 Japan: (also subscription enquiries)
KOICHI OGAwA
Siwertell 25 Siwertell.com

17
O.t.O. Research Corporation
takeuchi Building STERCORAT Hungary 53 stercorat.eu/en SRU combustion
1-34-12 takadanobaba
challenges
18 Shinjuku-Ku, tokyo 169, Japan
tel: +81 3 3208 7821
SOGAT 2018 61 sogat.org
fax: +81 3 3200 2889
Sulphur 2018 Conference 37 events.crugroup.com/sulphur/home
19 Previous articles from Sulphur from
1995 to the present are available
TSI Sulphur World Symposium 45 Sulphurinstitute.org/symposium 18
■ COVER FEATURE 4
20 digitally in PDf format. to make a
purchase, or for a list of available
articles, please see: www.bcinsight.com Weir Minerals 41 global.weir/brands Sulphuric acid
21 Copyright
Issued six times per year, or WorleyParsons 57 Worleyparsons.com
plant simulation
22 bi-monthly. All rights reserved.
No part of this publication may be
reproduced, stored in a retrieval ZAFARAN Industrial Group Co. IBC zafaran.net
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or by any means – electronic,
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25
Copyright owner.
Next issue: May/June 2018 SULPHUR

ISSUE 375
ISSN: 0039-4890

Design and production:

26 JOHN CReeK, DANI HARt l Sulphuric acid project listing
MARCH-APRIL 2018
27 l Asia refining book
28 Printed in England by: l Indonesia and its impact on copper and nickel markets
Buxton Press Ltd
Palace Road, Buxton, Derbyshire, l First ICOn™ sulphur degassing project
29 SK17 6Ae
l SO2 emissions from sulphuric acid plants
© 2018 – BCInsight Ltd
30
31 Closing date for advertisement space booking is 29 April 2018
Published by: BCInsight Ltd Southbank House, Black Prince Road
32 Southbank House, Black Prince Road For further information and to book advertisement space contact: London SE1 7SJ, England
London Se1 7SJ, england
tel: +44 (0)20 7793 2567 Tina Firman, Publishing Director: tina.firman@bcinsight.com Tel: +44 (0)20 7793 2567
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1

▼
2
3
■ CONTENTS
4
What’s in issue 375
Don’t forget the next issue
5
6
7 of Sulphur May/June 2018 ■ COVER FEATURE 1

8 Middle East
Sulphur
9
Conference,
10 Abu Dhabi
11
12 ■ COVER FEATURE 2

13 North Africa’s
14 phosphate industry
15
■ COVER FEATURE 3
16
17 SRU combustion
challenges
18
19
■ COVER FEATURE 4
20
Sulphuric acid
21
plant simulation
22
23
24
25 SULPHUR

26 ISSUE 375
MARCH-APRIL 2018
27
28
29
30
31
Southbank House, Black Prince Road
32 London SE1 7SJ, England
Tel: +44 (0)20 7793 2567
33 Fax: +44 (0)20 7793 2577
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